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EURO IV
FOREWORD
Congratulations.Younowownapieceofhistory!
TheRoyalEnfieldInterceptorisourheritage-inspiredmachine,builtforthemodern,intrepidtraveller.
Withyournewmachine,wemarkthereturnofoneofRoyalEnfield’smostlovedclassicmotorcycles-theInterceptor.
HarkingbacktoatimewhenallthatmatteredwasthattheCaliforniasunwasoutandthesurfwasup,thismotorcycleretainsthe
charmthatmadeitlegendary.
Designedtobesimpleandrobustwithsolidandpreciseengineering,theInterceptorhasbeenbuilttobeyourfaithfulcompanion
onrides andadventures, bigandsmall.Poweredbyourbrand-newair-cooled648cctwincylinderengineandrobusttwincradle
chassisdevelopedatourstate-of-the-arttechnologycentreintheUnitedKingdom,wehopeyouenjoyridingyourmotorcycleas
muchasweenjoyedbuildingitforyou.
This manual is your friend, philosopher, and guide when it comes to taking care of your motorcycle. In the pages that follow, you
will find ways of looking after your machine so that it remains a reliable partner in your travels and exploration for decades to
come.
Please do avail of all the services at your nearest Authorised Service Centre to make sure that your motorcycle gets the right
treatment which it so deserves. Please also read through the terms and conditions of warranty and other useful information in
thismanualbeforeridingointothesunshine.
Keepridingpure.
ToknowmoreaboutRoyalEnfield,ourproducts,andothernews,gotowww.royalenfield.com
2
All information in this manual is based on the latest product information available at the time of publication. Due to
continuous improvements, there may be discrepancies between the information in this manual and your motorcycle.
Royal Enfield reserves the right to make production changes at any time without prior notice and without incurring any
obligation to make the same or similar changes to motorcycle previously built or sold.
“© Copyright 2018 Royal Enfield (A unit of Eicher Motors Ltd.). All Rights Reserved. No part of this manual shall be
copied, distributed or otherwise dealt without the express permission in writing from Royal Enfield”.
All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical
specifications are subject to change without prior notice.
Avail further details on the products Repair and Maintenance Instructions at https://serviceinfo.royalenfield.com
through paid subscription.
NOTICE
Disclaimer
l This model fitted with “tubeless tyre” is provided with an inner tube.
l Failure to use an inner tube in a spoked wheel will cause deflation of the tyre resulting in loss of motorcycle control.
l The approved tyres marked with “TUBELESS” are suitable for use with inner tube.
Part No. RAM00010/A / Qty. 500 / Oct. ‘18
3
CONTENTS
Safety Definitions ........................................................................................................................................................................ 5
Personal and Motorcycle Information ....................................................................................................................................... 6
Safe Riding Tips / Guidelines ..................................................................................................................................................... 7
Rules of the Road ......................................................................................................................................................................... 13
Accessories and Luggage ............................................................................................................................................................ 16
Technical Specifications .............................................................................................................................................................. 18
Recommended Lubricants ......................................................................................................................................................... 26
Motorcycle Identification Numbers........................................................................................................................................... 28
Engine Number Details ............................................................................................................................................................... 30
Location of Key Parts................................................................................................................................................................... 31
Operation of Controls .................................................................................................................................................................. 34
Warning Indications and Safety Systems.................................................................................................................................. 45
Pre-Operational Checks .............................................................................................................................................................. 49
Running in Period ........................................................................................................................................................................ 50
Starting ......................................................................................................................................................................................... 52
Gear Shifting, Riding and Stopping ........................................................................................................................................... 56
4
CONTENTS
Parking.......................................................................................................................................................................................... 60
Tools Kit ........................................................................................................................................................................................ 62
Minor Maintenance Tips ............................................................................................................................................................. 63
Long Trip Precautions .................................................................................................................................................................. 100
Washing Procedure ..................................................................................................................................................................... 102
Storage Precautions .................................................................................................................................................................... 104
TroubleShooting .......................................................................................................................................................................... 105
Wiring Diagram ............................................................................................................................................................................ 113
Periodical Maintenance Chart.................................................................................................................................................... 116
Service Maintenance Record ...................................................................................................................................................... 120
Warranty Terms and Conditions................................................................................................................................................ 123
Emission Warranty ...................................................................................................................................................................... 126
EVAP.............................................................................................................................................................................................. 132
Environment Care ....................................................................................................................................................................... 134
Notes ............................................................................................................................................................................................. 136
5
SAFETYDEFINITIONS
Theinformationgiven under thetitles:Warning, Cautionand Note are for your safety and for the careand safety toyour
motorcycleandothers. Pleasereadthesecarefullyandifdisregardedmayresultininjurytoyourselforothersanddamages
tothe motorcycle.
NOTE
Indicates important and useful messagesfor better understanding.
CAUTION
Thismessage,if disregarded, may result indamage to the motorcycle.
WARNING
Indicates a potentially hazardoussituation. Disregarding this message may result ininjury to rider or other persons.
6
PERSONALANDMOTORCYCLEINFORMATION
Name
Door No./Street
Locality/Town
City Country
Contact
Res : Off :
Mobile : Email :
Licence No. Valid till :
Model Color :
Engine No.
VIN. No.
Tyre make Front : Rear :
Tyre Nos. Front : Rear :
Battery make Battery No.
Sold by
Date of Sale
7
SAFERIDINGTIPS/GUIDELINES
n Before operating your new motorcycle, we request youtocarefullyread and followthe operating and maintenance
instructions detailed inthis manual for the safety of your own, your motorcycle, and also that of others.
n Knowand adhereto the rules of the road withrespect toyour driving country.
n Before starting the motorcycle, checkfor proper operationof brakes, clutch, gear shifter, handle bar controls,tyre
pressures,fuel and oil levels,etc.
n Use onlygenuine Royal Enfield spare partsandapproved accessories. Use of other manufacturer’spartsmayaffect
the performance of your motorcycleand render themotorcycle void of warranty. Visit your RoyalEnfield Authorised
ServiceCentre fordetails.
n Whenever refuelingyour motorcycle,please exercise utmost cautionand carefullyobserve thefollowingguidelines.
« Refuel ina well ventilated area with the engine turned off condition.
« Open thefuel filler cap slowly.
« Switch OFF mobile phones and other hand held electronic devices.
« DONOT smokeand pleaseensure thattherearenoopenflamesor sparksnearthe motorcycle,whenrefuellingOR
servicingthe fuel system.
8
SAFERIDINGTIPS/GUIDELINES
WARNING
Royal Enfield cautionsyouagainst theuse of certainnonstandard partssuchasaftermarket andcustommade extended
front forks or suspensions, whichmay adversely affect performance and handling. Removing or altering original parts
may adverselyaffectperformance and could result inaccident.
n A new motorcycle must be operated according to the special running-in-procedure. See running-in-procedure
mentioned inrespectivesection.
n Operate motorcycle only at moderate speeds and out of traffic until you have become thoroughly familiar with its
operation and handling characteristics under all conditions.
n DO NOT exceed the legal speed limit or ride too fast for existing conditions. Alwaysreduce speed when poor riding
conditions exist. High speed increases the influence of any other condition affecting stability and increases the
possibility of loss of control.
« DONOTfill the tankto itsbrim. Please fill fuel till thebottomof anti splashplate,soastoleavesufficient air space
in the fuel tankto allowfor fuel expansion.
9
SAFERIDINGTIPS/GUIDELINES
NOTE
If you are aninexperienced riderwerecommend thatyou obtainformaltrainingoncorrect motorcycleriding techniques
andbecomethoroughlyfamiliarwith the operationofyourmotorcycle.Newridersshould gainexperience under various
conditionswhile driving at moderate speeds.
Pay strict attention to road surfaces and wind conditions. Any motorcycle may be subject to the following upsetting
forces:
« Wind blasts from passing vehicles.
« Roughor uneven road surfaces.
« Slippery road surfaces.
Theseforcesmayaffect thehandling characteristicsof your motorcycle.If thishappens,reduce speedof the motorcycle
toa controlled condition. Donot applybrakeabruptly.
n Operate your motorcycle defensively. Remember that a motorcycle does not afford the same protection as an
automobile inan accident. One of the most commonaccidentsituations occurs when the rider / driver of the other
motorcycle / vehicle fails tosee or recognise a motorcycle and turns intothe oncomingmotorcyclist.
10
SAFERIDINGTIPS/GUIDELINES
n Wear an approved helmet, clothing, and footwear suited for riding a motorcycle. Bright/light colours are best for
greater visibility intraffic, especiallyat night. Avoid loose,flowing garmentsand scarves.
n Whencarryinga pillionrider, it is your responsibilityto instruct themon proper ridingprocedures.
n DO NOT allow other individuals, under any circumstances, to operate your motorcycle unless you know they are
experienced, licensed ridersand are thoroughly familiar with the operating conditionsof your motorcycle.
WARNING
Regularlyinspectshockabsorbersand frontforksandlookfor leaks.Replace wornoutparts.Wornout partscanadversely
affect stability and handling.
WARNING
Foryourpersonal welfare,allthe listed serviceand maintenance recommendationsshouldbeperformed.Lack of regular
maintenance at thesuggested intervalsmayaffect thesafe/durability/longevityoperation of your motorcycle.
11
SAFERIDINGTIPS/GUIDELINES
WARNING
Avoid anycontact withthe exhaust systemwhenhot.Wear clothing that will completely cover the legswhile riding. The
exhaustsystem getsveryhot whenthe engine isrunningand remainstoo hot totouch, evenaftertheengine isturned off.
Failure to wear proper or protective clothing could result in seriousinjury.
WARNING
Exhaust gas contains poisonous carbon monoxide and chemicals, known to cause cancer, birth defects or other
reproductivedefects.
WARNING
Motorcycle batteries containlead, acidsand chemicalsknowntocausecancer,birthdefectsor other reproductiveharm.
Exercise extreme cautionwhile handlinga battery, wash hands thoroughly whenever a battery is handled.
12
WARNING
ConsultyourRoyalEnfieldAuthorisedServiceCentreregardinganyquestionsorproblemsthatoccurintheoperationofyour
motorcycle. Failure to doso mayaggravate aninitial problem, cause costlyrepairsand jeopardize your personal safety.
WARNING
DO NOT tow a motorcycle. The steeringand handling of the towed motorcycle will be impaired due to theforce of the
towline. If a motorcyclemust be transported, usea truckor a trailer.
WARNING
DO NOT pull a trailer behind a motorcycle.Towing a trailer may causereduced braking efficiency, tyre overloading and
SAFERIDINGTIPS/GUIDELINES
unstable handling, asit may cause loss of control of the motorcycle inthe front, leading to anaccident.
13
RULESOFTHEROAD
n Be sure your number plate isinstalled in the positionspecified bylawand it isclearly visible at all times.
n Ride atasafe speed that isconsistent withthe typeof road surfaceyouare on.Paystrict attentionwhile ridingonthe
following surfaces :
« Dusty
« Oily
« Icy
« Wet
« Sand
n Watchforloose debris,suchasleaves, slippery substancesorgravelthat canhamper thestabilityofyour motorcycle.
n Keep to the correct sideof the road centre line whenmeeting oncoming vehicles.
14
RULESOFTHEROAD
n Actuateyour turn signalsand exercisecautionwhen passing other vehicles going inthe same direction. Never tryto
passanother vehicle going inthe same direction at street intersections, on curves, or whengoing up/or down ahill.
n At street intersection give the right-of-way to the motorcycle on your left or right. DO NOT presume you have the
right-of-way.
n Adhere totherulesof theroadwithrespect toyour countrywhenpreparingto stop, turnorpass.Whileturningeither
right or left, watchfor pedestrians, animals,as well asother vehicles.
n All traffic signs, includingmanual controlsat intersections,should be obeyed promptly. SLOWDOWN at traffic signs
near schools and CAUTION signs at railroad crossings.
n When intending toturn, signal at least 100 feet (30.5meters) beforereachingthe turning. Beclose to
the centre line (unlesslocal rulesrequire otherwise),slowdownand then turncarefully.
n Never jump a traffic light. When a changeisimminent fromGOtoSTOP(or vice versa)at intersections,
slowdown and wait for the light to change togreen. Never runthrough a yellow or red traffic light.
n DO NOT leave the curb or parking area without signalling. Be sure your way is clear to enter moving
traffic. A movingline of traffic always has the right-of -way.
15
SIDE VIEW MIRRORS
Yourmotorcycle isequipped withconvex mirrorsand have a curved surface.
This typeof mirror is designed to give a muchwider view of the rear than a
normal flat mirror. However, vehiclesand other objects seen in this type of
mirror will looksmaller and farther awaythan when seenin a flat mirror.
Use care whenjudging the size or distanceof vehicles / objectsseen inthese
mirrors.
NOTE
Toestablish the relative distance of vehicles /objectsbehind your motorcycle throughthemirrors,adjust eachmirror in
sucha way, that a small portionof your shoulder isvisible and alarge portionbehind your motorcycle isseen clearlywith
RULESOFTHEROAD
reference to your ridingposture.
n Whenparking themotorcycle,parkona firm and flat surface to prevent it fromfalling over.
n Protect yourmotorcycleagainsttheft.Afterparkingyour motorcycle,ensurethat the steeringhead islockedand then
remove the ignitionkey.
16
ACCESSORIES AND LUGGAGE
Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested
alongside the motorcycle.
Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying
additional weight. (Max. pay load: 200 kg)
Please adhere to the following guidelines when carryinga pillion, luggage or when fitting any accessories.
n Keep luggageweight concentrated close to the motorcycle and aslowaspossible;thisminimizes suddenshift inthe
motorcycle’scentre of gravity.
n
n
Distribute weight evenly onboth sides of the motorcycle.
DO NOT exceed 110km/h / 70 mph when riding solo, carrying a pillion or payload on an accessory equipped motorcycle.
n DO NOTload bulky itemsbehind the rider or add weight tothe handlebarsor front forks.
n DO NOT exceed 6.6 pounds (3 kgs) maximum weight ineachRoyal Enfield Genuinemotorcycleaccessory pannier.
n Re-checkthe luggage periodicallytoensureit issecured and will not shift whileriding.Accessoriesmounted loosely
may affect the ridingof the motorcycle and affect the handling and stabilityof the motorcycle.
n Large surfaces such as fairings, windshields, backrests and luggage racks can adversely affect handling of the
motorcycle. Use Royal Enfield Genuine Motorcycle Accessories which are model specific and follow installation
procedure.
17
ACCESSORIES AND LUGGAGE
WARNING
DONOTload weight or install accessories incorrectly onthe motorcycle. Doing so may affect the motorcycle’s stability,
handling characteristics and safe operation and could result inan accident causing serious injury or loss of life.
WARNING
Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested
alongside the motorcycle.
WARNING
Royal Enfield cautionsyou against use of nonstandard partssuchasaftermarket and custommade extended front forks
which mayadversely affect the performance and handling of the motorcycle. Removing or altering original parts may
adversely affect the performance of the motorcycle, causing an accident, which could result in serious injury or loss of life.
WARNING
DO NOT ignore model /design specifications. Doing soconstitutes bothmotorcycleand accessories misuse which may
adversely affect the handling and performance of the motorcycle causing an accident, which could result in serious
injury or lossof life.
18
TECHNICALSPECIFICATIONS
ENGINE
Engine Type ........................................... Inline Twin Cylinder, 4 Stroke, SOHC
Bore ........................................................ 78mm
Stroke ..................................................... 67.8mm
Swept volume ....................................... 648cc
Compression ratio ................................. 9.5:1
Max Power ............................................. 34.9 kw @ 7250 rpm
Max Torque ............................................ 52.3 Nm @ 5150 rpm
Idle RPM ................................................. 1200+80 RPM
Starting................................................... E-Start
Air filter element ................................... Paper element
Lubrication ............................................ Forced lubrication, Wet sump with pump driven oil delivery
Gear Box ................................................. 6 Speed Constant Mesh
19
Engine oil capacity Dry Fill ....... 3.9 litre / 1.03 imperial gallon
Refill .......... 3.1 litre / 0.82 imperial gallon
Engine oil grade .................................... TOTAL ELF MOTO 4 TECH SAE 10W50 API SL, JASO MA2, SYNTHETIC
Fuel Supply ............................................. Fuel Injection
Cooling .................................................. Air cooling
IGNITION SYSTEM
Ignition................................................... Digital Spark ignition
o
Ignition Advanced ................................ 11.25 BTDC
Spark Plug .............................................. BOSCH UR5CC
Spark Plug Gap ...................................... 0.7 to 0.8 mm
TECHNICALSPECIFICATIONS
20
TRANSMISSION
Clutch ..................................................... Wet multiplate
Primarydrive .......................................... Gear
Primary ratio ........................................... 2.05: 1
Gear box ................................................. 6 Speed Constant Mesh
st
Gear Ratio ............................................... 1 2.615:1
......................................................... nd
2 1.813:1
......................................................... rd
3 1.429:1
......................................................... th
4 1.190:1
......................................................... th
5 1:040:1
......................................................... th
6 0:962:1
Secondary drive ...................................... Sprockets and Chain(5/8” Pitch)
Secondary Ratio.....................................2.533:1
TECHNICALSPECIFICATIONS
21
CHASSIS
Frame ..................................................... Steel Tubular, Double Cradle Frame
Suspension
Front................................................ 41 mm Front Fork, 110 mm travel
Rear ................................................. Single Coil-over Shocks, 88 mm travel
Hydraulic Disc Brakes ........................... Front and Rear with ABS system.
............................................... Front: 320 mm disc, ABS
................................................. Rear: 240 mm disc, ABS
................................................. ABS: BOSCH 9.1
Brakes:
Brake Fluid:
.............................................. Grade: DOT 4
......................................... Capacity: Front: 50 ml Rear: 100 ml
Tyre size:
Front................................................
Rear.................................................
Dual Channel ABS
100/90-18, Pirelli Phantom Sports Comp
130/70-18, Pirelli Phantom Sports Comp
TECHNICALSPECIFICATIONS
22
TECHNICALSPECIFICATIONS
TyrePressure:
Solo
Front................................................
Rear..................................................
Front................................................ 32 psi/2.20 kg/cm
Rear.................................................. 39 psi/2.74 kg/cm
Fuel Type ................................................ Unleaded Gasoline
Ethanol content...................................... E10or less
Minimum Octane Rating ....................... 91 RON (Research Octane Number) or Higher
Induction ................................................ Fuel Injected
Fuel tank capacity ................................... 13.7* litre / 3* imperial gallon
Low Fuel Warning .................................. 2.9* litre /0.63*imperial gallon
DeadStock.............................................. 0.75* litre /0.16* imperial gallon
* The above values are approximate and the actual fuel filling capacitywill vary from the valuesmentioned.
32 psi/2.20 kg/cm
36 psi/2.53 kg/cm
With Pillion
Steering Lock.......................................... Combination Lock
23
TECHNICALSPECIFICATIONS
WA RNING
Using bulbs/ other electrical accessories other thanspecified rating maylead toover loading / erratic behaviour /
premature failure of electrical system. Modificationsonthe motorcycle which arenot approved byRoyal Enfield may
not only disqualify for warranty, but will alsoaffectsthe performance of the motorcycle.
ELECTRICALS
System .................................................... 12V - DC
Generation.............................................. Alternator
Alternator Output ................................... 156 W @ 1100 rpm
Battery .................................................... 12V - 12 Ah VRLA
Head lamp .............................................. 12V, H4 60/55 W
Brake/Tail lamp ...................................... 12V, P21/5W (Halogen)
Turn signal .............................................. 12V, R10W
Instrument Cluster .................................. Digital Instrument Cluster withLCD
Horn ........................................................ 320 Hz Low and 420 Hz High Tone
StarterMotor .......................................... 12V, 0.8 KW
24
TECHNICALSPECIFICATIONS
DIMENSIONS
Rake ........................................................ 24 degrees
Front Wheel ............................................ 18 M/C xMT 2.50
Rear Wheel ............................................. 18 M/C x MT3.50
Length..................................................... 2119 mm
Width .............................................. 857 mm (with mirrors)
Height .............................................. 1120 mm
Wheel base ............................................. 1398 mm
Ground Clearance................................... 174 mm
25
WEIGHTS
Kerb weight (90% Fuel and Oil) ........... 213 kg
Max. payload.......................................... 200 kg(Inclusive of rider mass)
n Values / dimensions given above only for your guidance.
n In view of continuous improvements being done on our products, the specifications could change without prior
TECHNICALSPECIFICATIONS
NOTE
notice.
26
RECOMMENDEDLUBRICANTS
Capacity * DO NOT Mix DOT 4 or
other brake fluids together.
Engine Oil
CAUTION
Use of wrongoil grade will reduce thelife of the moving partsand seriously affect performance.
NOTE
Recommendation subject to change without notice.
Front Fork Oil Brake Fluid
Brake System
Capacity
Grade DOT4
TOTAL ELF MOTO 4 TECH SAE
10W50 API SL, JASO MA2,
SYNTHETIC
1st DryFill :
3.9 litre /
1.03 imperial gallons
Grade
Routine Oil Change :
3.1litre/
0.82 imperial gallons
Capacity
Grade 2W 25 HPCL
473 ml / Fork Front: 50 ml
Rear:100 ml
Dual Channel ABS
27
ISO 14001 OPERATION CONTROL PROCESS
As per the guidelines in ISO 14001 Environmental Management System, customers are advised to carry out timely
replacement of engine oil, fork oil and brakefluid, ONLY througha Royal Enfield Authorised Service Centrefor the safe
disposal of the used oilsto prevent environmental pollution.
In case theoilsare replaced privately, it isadvised toensure theold / removed oilsare collected carefully and disposed
through a certified disposal agency.
Similarly, hazardous waste such as old / discarded batteries, tyres, tubes, cables, gaskets, oil filters etc. should also be
disposed off carefully and properly, througha certified disposal agency.
28
MOTORCYCLEIDENTIFICATIONNUMBERS
The VIN is a17digit number punched on the right side steering head tube in the formof label.
Sample VIN : ME3 X X XX X X J X X X X X X X
Manufacturer’scode
Type of Frame
Type of Engine
Commercial Name
Ignition System
Transmission Type
Production Year
Assemblyfactory
ProductionSerial No.
(2017:H, 2018:J, 2019:K)
(C-Chennai, K-Kanchipuram)
29
CHASSIS NUMBER
MOTORCYCLEIDENTIFICATIONNUMBERS
Punched on the steering head tube right side
VIN INFORMATION LABEL
It isillegal totamper withthe VIN information label as it is the only meansof identifications of the motorcycle.
CAUTION
M
E
3
C
N
E
H
T
6
H
K
0
0
0
0
0
1
30
ENGINE NUMBER - DETAILS
The enginenumber is punched above the oil filter location. it isthemeansof identificationof the engineserial number
and its production details. It isillegal to tamper with the engine number as it is the only means of identifications of the
engine.
Engine Family
Engine Capacity
Type of Cooling
Transmission
Fuel Feed
Place of Manufacturing
Production Month
Year of Manufacturing
(2017:H,2018:J, 2019:K)
P 7 A 6 F K H 1 000086
(A - Jan., h - Aug., K - Sep., N - DEC.)
(0-Chennai, 1-Kanchipuram)
Production Serial Nos.
31
LOCATIONOFKEYPARTS
1. Horn Button
2. Turn Signal Switch
3. ClutchLever
4. Day Flash Switch
5. HighBeam/ LowBeamSwitch
6. Instrument Cluster
7. Ignition Switch
8. Malfunction Indicator Lamp
9. RPM(Tacho)Meter
10. Engine Kill switch
11. Electric Start Switch
12. Fuel Tank Cap
km/h
00
2
0
00
4
0
00
6
0
00
80
00
100
00
120
00
14
0
00
16
0
00
18
0
00
20
0
00
E
ODO 00
F
km
00
OF
F
R.P.M. x 1000
1
00
2
00
3
00
4
00
5
00
6
00
7
00
8
00
9
00
ABS
N
45
2
1
3
89
7
6 10
11
12
LOCATIONOFKEYPARTS
1. Right Trafficator Rear
2. Right Trafficator Front
3. Horn
4. StarterMotor
5. BrakePedal
6. Brake LeverRear
7. Right Side Panel
8. Brake Lever Front
32
8
2
3
4
5
6
7
1
33
LOCATIONOFKEYPARTS
1. Left Trafficator Front
2. Left Trafficator Rear
3. Left Side Panel
4. SideStand
5. Centrestand
6. Gear Change Pedal
7. Spark plug
7 6 4
5
2
1
3
34
STEERING LOCK
n Turnthe handle bar toextreme left or right position.
n Pushthe keyinside at“OFF”position,pressandfurther turntoanticlockwise directionto
lockthe steeringand remove the key.
n
OPERATIONOFCONTROLS
IGNITION SWITCH
To unlock, insert the key in steeringat lock position, and turn clockwise direction.
NOTE
n Key is common for ignition, petrol tank lock, steering lock and side panels.
n Key can be removed from fuel tank, side panel only in locked position from the key slots.
OFF: Steering unlock, ignition “OFF”
ON: Steering unlock, ignition “ON”
35
OPERATIONOFCONTROLS
FUEL TANK CAP
n Lift keyflap onfueltank cap and insert key.
n Turn key clockwise to open.
n Presscap tolockwithkey inposition.
n Remove key from cap and close flap
WARNING
n DO NOToverfill the fuel tank.
n Fill fuel only till the bottomof anti splash plate.
n Over fillingmay result ingasoline entering the EVAP canister and may damage the EvaporativeEmission System.
CAUTION
Gasoline vapour ishighly explosive.Please ensure there are noopen flames or sparksnearby while refueling andfill fuel
onlyina wellventilated area.
Pleaseensuregasolinedoesnotspillonpaintedsurfaces.Incasefuelspillsoverthepaintedsurfaceswipeitoff immediately
as it mayleavea permanent stain.
Do not smoke while refuelingor whenfuel tankcap isopen.
36
FUEL FILLING LEVEL
1. Fuel filler collar
2. Anti splashplate
OPERATIONOFCONTROLS
3. Maximum fuel level
ENGINE KILL SWITCH
Engine "OFF" Engine "ON"
CAUTION
n Turn off ignition switchwhen engine is not running. Failure to do sowill discharge the battery due tothe headlamp
being continuously "ON".
37
OPERATIONOFCONTROLS
E-START SWITCH
Depress and hold untill engine starts for a maximum of 5 seconds.
HI BEAM / LOW BEAM SWITCH
High beam Low beam
HORN
Pressthehorn button to sound horn.
n When the headlamp is in ON condition “High / Low beam” will be selected by toggling
the switch. Highbeamindicator lamp located ininstrument cluster will glowwhen high
beamisselected.
38
OPERATIONOFCONTROLS
TURN SIGNAL SWITCH
"OFF" (Push to cancel)
Right turn signal "ON"
Left turn signal "ON"
DAY FLASH
Press theswitchfor Dayflash.
Pushthebuttonfrom“OFF” positiontoeither left orright before turning as neededand restore to“OFF” positiontostop
blinking.
39
OPERATIONOFCONTROLS
SIDE PANEL LEFT
n Toaccesstheleft side panel remove theseat andretainingscrew, pulland disengage the
side panel fromlocater and gentlyremove the side panel.
SIDE PANEL RIGHT
n Turn keyclockwise tounlock the side panel.
n Pull the side panel along with keytogently remove the sidepanel.
40
INSTRUMENT CLUSTER
This instrument cluster consists of the following:
1. Speedometer
2. Odometer
3. Selection Button
4. Trip Meter 'A' and 'B'
5. Turn Signal Indicator
6. Hi beam Indicator
7. Engine Malfunction Indicator
8. BatteryLow Voltage Indicator
9. Fuel Level Indicator
10. ABS Indicator
OPERATIONOFCONTROLS
11. Neutral Indicator
12. Low Oil Pressure Indicator
13. Tachometer
1 2 4 9 3 13 5 7 6 81011 12
41
NOTE
The last selection mode will be displayed whenever ignition isswitched "ON".
2. ODOMETER
The default display inthe odometer isthe total kms/miles, the motorcycle hascovered
1. SPEEDOMETER
The Speedometer indicates the speed at which motorcycle is travelling and has both kms/
OPERATIONOFCONTROLS
miles calibration.
WARNING
It isillegal totamper withthe odometer display or reset the total kms/miles, themotorcycle hascovered.
It isillegal to ride the motorcycle after disconnecting thespeed sensor of the motorcycle.
42
WARNING
Do not attempt to changeany setting while riding the motorcycle. It maycause lossof control leading to an accident.
4. TRIP METER A AND B
A light push for less than one second on the select button switch will change the display from odometer Trip ‘A’. Again
another press onthe select button switchwill change the display from Trip ‘A’ toTrip ‘B’.
NOTE
1. Set the displayasTrip ‘A’or Trip ‘B’ ascurrent mode.
2. Presstheselect buttonfor more than3seconds.
3. Automatically the display will become zero.
OPERATIONOFCONTROLS
3. SELECTOR BUTTON
The selector knob will help toselect between odometer, Trip ‘A’ or Trip ‘B’.
43
OPERATIONOFCONTROLS
5. TURN SIGNAL INDICATOR
Indicates that either the left or right indicators are “ON”.
6. HI BEAM INDICATOR
Indicates that the high beam head lamp is “ON”.
7. ENGINE MALFUNCTION INDICATOR LAMP
AMalfunctioning indicator lamp (MIL) isprovided in the tachometer.
Whenboththe ignitionandengine kill switchisin“ON” position and after vehicle isstarted,the
MILwill glowforfewsecondsandswitch“OFF” thisindicatesthat all thefunctionsofElectronic
fuel injection (EFI) system is functioning normally. In the event of any malfunction in the EFI system MIL will glow
continuously.Itisrecommended totakethemotorcycletoanearestRoyalEnfieldAuthorised ServiceCentreforadetailed
inspection and correction of EFI system.
44
OPERATIONOFCONTROLS
8. BATTERY LOW VOLTAGE INDICATOR
When the ignition switch is turned in“ON” position, low voltage indicator symbol will glow.
As soon as theengine isstarted thebattery lowvoltage indicator turns “OFF” automatically.
Incase the batteryvoltageisbelow12 volt and thebatteryisnot charging when the engineis
started,the batterylow voltageindicator will continue to glow inthe instrument cluster.
CAUTION
DO NOT ride the motorcycle if the battery low voltage indicator is glowing continuously and please get the charging
systemchecked throughan Royal Enfield Authorised Service Centre immediately.
45
WARNINGINDICATIONSANDSAFETYSYSTEMS
Your motorcycle is fitted with the following warning indications and safety systems:
9. FUEL LEVEL INDICATOR
Thefuel level indicator indicates the level of fuel in thefuel tank.
Thedisplaybarsofthefuelmeterfadestowardstheempty(E)whenthe fuelleveldecreases
fromfulltank level (F).
The last bar of thefuel level indication inthe instrument cluster will blinkcontinuously whenthe fuel is less than 3litre
(0.8 imperial gallon).
Please do not ride the motorcycle with the low fuel indication blinking continuously as it may not only result in the
motorcycle running out of fuel, but will alsocause seriousdamagetothe fuel pump. Please refuel as soonasthe lowfuel
indication starts blinking.
46
WARNINGINDICATIONSANDSAFETYSYSTEMS
10. ANTI-LOCK BRAKING SYSTEM (ABS)
Anti-Lock Braking System (ABS) will help prevent the brakes from locking the wheels,
during sudden application of the brakes at high speeds or at low friction surfaces. This will
help the rider to have better traction and control over the motorcycle and prevent the
motorcycle from skidding which can cause an accident.
Intheeventofasuddenandhardapplicationofthebrakesbytherider,thesensorsinthebraking
system will signal the ABS modulator to momentarily and continously reduce the hydraulic
pressure andthereby prevent the brakesfromlockingthewheelswhile reducingthespeed of
the vehicle. This will help the rider to control the motorcycle.
An ABS indicator lamp is provided inthe cluster (as shown in the adjacent image) to warn the rider in the event of any
malfunction of the ABS.
When the ignition and engine kill switch are switched in “ON” position the ABS sign will glow and remain "ON" till the
motorcycle attains a speed of 5 kmph / 3 Mph and turns “OFF”. This indicates the ABS is functioning properly. If the
ABS indicator lamp does not switch "OFF" and remains continuously "ON" at higher speeds, it is recommended not to
drive the ABS motorcycle. Get the brake system inspected and corrected through a nearest Authorised Royal Enfield
Service Centre. Failure to do so can result in a serious injuries and loss of life.
47
WARNINGINDICATIONSANDSAFETYSYSTEMS
CAUTION (ABS)
ABSisa safetyfeature to help prevent lockingof wheelsduring panic applicationof brakes. It isby no meansa substitute
for good riding practices and anticipatory braking.
Please ridecarefullyand applybrakescautiously,especiallywhile cornering.ABS cannot estimatethe“weightshifts”and
momentumof the motorcycle while negotiating a corner and therefore prevent skidding due tolossof traction.
Please anticipatethestopping distance requiredfor thespeedoftraveland applybrakeswellinadvanceso astobring the
motorcycle toa safe stop.
Please applybothbrakes simultaneously to stop withbetter tractionand control of the motorcycle.
Failure toadhere tothe above cancausean accident resulting inseriousinjuries and loss of life.
48
WARNINGINDICATIONSANDSAFETYSYSTEMS
DO’S AND DONT’S : (ABS)
12. LOW OIL PRESSURE INDICATOR
This indicator glows whenever the oil pressure is too low. When the ignition switch is in “ON” position with the
engine not running condition the indicator goes off when the engine oil pressure is high enough / normal condition.
11. NEUTRAL INDICATOR
This indicator glows when the vehicle is in neutral position.
DONT’S
DO’S
n While starting the engine do check the ABS indicator glows “ON” and
turnsOFF when the vehicle speed exceeds 5 km/h (3.1mph).
n Please check thebrake fluid at “MAX” level inthe front and rear brake
reservoir and ensurethere isno leakinthebrake systems.
n Applyboth thebrakes simultaneouslyfor better efficiency.
n In the event of theABS indicator remaining continuously “ON”, please
takethemotorcycletoanearestAuthorisedRoyalEnfieldServiceCentre
toinspect thebrakesystem.
n DO NOT RELEASE the brake lever/
pedalwhenpulsationsarefeltduring
hard application of the brakes in an
emergencysituation. Thepulsations
only indicate that the ABS is
activated.
n DONOTAPPLYonlythefrontORrear
brake as it can lead to inefficient
braking.
49
ROLL OVER SENSOR
In the event of motorcycle falling over on either of its sides withthe engine runningand the gear engaged the roll over
sensor will disable boththe ignitionand fuel systemsand switch“OFF” the engine. Thisistoprevent further damage to
the motorcycle and the rider.
Toreset the roll over sensor and reactivatetheignitionand fuel systems.
n Ensure the motorcycle isparked upright on afirm surface.
n Ensure gear is inneutral position and theneutral lamp isglowingin the instrument cluster.
n Turn“OFF” ignition andswitch“OFF” engine kill switch, wait for a few secondsand turn“ON” the Ignitionand switch
WARNINGINDICATIONSAND SAFETYSYSTEMS
“ON” engine kill switch once again, tostart the engine.
13. TACHOMETER
Thisindicates the engine speed inRPM.
CAUTION
When the indicator glows continously and if the engine speed is above idle, stop the vehicle immediately and get the
engine inspected and corrected througha nearest Authorised Royal Enfield Service Centre. Failure to do so can cause
engine damage.
50
PREOPERATIONALCHECKS
WARNING
For your personal welfare and safety,all the pointsmentioned above should beperformed periodically.Failure todoso
may affect safe operation, damage your motorcycle and could result in anaccident causingseriousinjury or lossof life.
Acareful checkonthefollowing aspectsmust be carried out everytimebefore ridingand especiallyafter longperiodsof
storageto determineif anyadditional maintenance is necessary.
1. Adequate fuel inthe tankfor the journeyplanned.
2. Tyresfor correct pressure, abrasionsor cuts.
3. Ensure chainfor proper tension and sufficient lubrication.
4. Brakes, clutch, steeringand throttle for proper responsiveness.
5. Handle bar controls for smooth operation.
6. Engine oil level.
7. Wheel spokes for proper tightnessand damage.
8. Headlamp, tail lamp, brake lamp and indicator lamps for proper functioning.
9. Proper functioning of all the warning lamps in the instrument cluster.
51
RUNNING INPERIOD
The Royal Enfield Motorcycle as you would be experiencing iscapable of consistent high speeds. However as with any
new motorcycle, a “RUNNING-IN” procedure is essential to help in proper “Bedding-In” of the various moving parts in
your motorcycle and toachieve optimum performance subsequently.
1. DO NOT exceed maximum specified pay load.
2. Warmup the engine for a few minutesat idlingspeed toallow engineoilto lubricateallthemovingpartsinthe engine
beforeriding the motorcycle.
3. Avoid full throttleoperation and donot ride at constant throttlecontinuously.Vary thespeed by 10%while riding.
4. It is recommended to use half clutch condition when commuting in the city traffic condition alone (Engine RPM
around idling to2000 RPM) at 1st gear condition. In Other gears and higher RPM avoid using half clutch which will
proportionately reduce the clutchlife. Duringacceleration/deceleration disengagethe clutchcompletely, shift the
gear and engage the clutch gradually (Not too slowly).
5. Ride at proper speed and avoid suddenaccelerationsand braking.
6. Avoid riding motorcycle continuously for over an hour, it is recommended totake brief stop.
52
RUNNING INPERIOD
During the first 2000Kms of run, donot exceed the speed limits as shown in the table below.
Motorcycle Speed
Gear First 500 kms 501 - 2000 kms
NOTE
The belowtable indicates the recommended engine speed in rpmfor optimum performance of the engine.
DistanceCovered Max.Engine Speed
0 to800 kms( 0 to 500 miles) 4000 rpm
800 to 1600 kms ( 500 to 1000 miles) 6000 rpm
20 kmph
15 kmph
1
30 kmph
25 kmph
2
40 kmph
30 kmph
3
55 kmph
45 kmph
4
70 kmph
60 kmph
5
85 kmph
75 kmph
6
53
STARTING
n To shift into neutral, move the motorcycle back and forth gently, while
simultaneously shifting the gear. Ensure gear is in neutral position and the
neutral lamp is glowing in the instrument cluster.
n Turn ignition key to “ON” position and engine kill switch on right hand side
handle bar to “RUN” position .
54
STARTING
n When both the ignition and engine kill switch is in "ON" position and after the
vehicle is started, the MIL will glow for a few seconds and turns “OFF”, this indicates
that all the function of the electronic fuel injection (EFI) system is functioning normally.
In the event of any malfunction in the EFI system the MIL will glow continuously.
CAUTION
n In casethemalfunctionindicator DOES NOTturn “OFF”, get the motorcyclechecked
throughanRoyal Enfield Authorised Service Centre for rectification.
n Checkthefuellevel indicator intheclusterfor adequate fuelinthefueltank. Incase the
last bar is blinking continuously, it indicates low fuel leve l in the tank. Please re-fuel
immediately.
55
n Depress and hold electric start switch until engine starts for a maximum of
STARTING
n Disengage clutch by pulling in the clutch lever and hold it in depressed condition.
NOTE
Incase theenginedoesnot startwithin5second, releasestarter switchand waitfor about 5second before attempting to
start the engine again.
5 seconds.
56
WARNING
Please exercise extreme care while ridingthe motorcycle.Failure to do socanresult inanaccident causing injurytoyou
or toother roadusers/ passerby.
CAUTION
If the enginedoes not start. DO NOT hold the starter switch in depressed condition for long periods, this will cause the
batterytodrainbelowthethresholdlevelof10volt.PleasegetthemotorcyclecheckedthroughanRoyalEnfieldAuthorised
ServiceCentreto identifyand correct the reasonfor not starting.
CAUTION
NEVER accelerate assoon as the engine starts, especially in cold condition. The engine should be allowed to run in idle
RPM for at least 2 minute for the engine oil to circulate and lubricate all the internal moving parts and for the engine
temperature to raise.Failure toadhereto thisimportant information will causeseriousdamage tothe engine internals.
Accelerate only after the idlingRPMhas stabilised and it isconsistent.
STARTING
n Ensure side stand isin fullyretracted position. Failure to do so will cause the engine to switch“OFF” as soon asgear
is engaged.
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GEARSHIFTING,RIDINGANDSTOPPING
The clutch lever must be fully depressed before attempting a gear shift. Failure to fully
depress the clutchlever will cause a roughstart ORstalling of the engine besides causing
damage totransmission parts.
n Whenthe vehicle isinNeutral position,press gear shift lever downwithtoe toengage
1stgear.
GEAR SHIFT PATTERN
1-- N -- 2 -- 3-- 4 -- 5-- 6
58
GEARSHIFTING,RIDINGANDSTOPPING
CAUTION
n Iftheclutchleverisreleasedabruptlyand throttle openingisdone insufficientlythemotorcyclewillhavearoughstart
and cause the engine tostall.
n If the accelerationisveryhighand clutchlever isreleased abruptly, it will cause motorcycletomovesuddenly,which
willleadtolossof control leading toanaccidentresultingininjuryand orlossoflife torider/ otherroad users/ passed
by, besidesdamage tothe motorcycle.
n Always exercise utmost caution while releasing clutch and riding the motorcycle.
n Lift gear shift lever up withtoeto shift to 2nd and subsequent gears.
n As soon asthemotorcycle reachesa speed of 20 kmph in1st gear position,shift to
2nd gear and tohigher gearsas the speed of themotorcycle increases.
59
GEARSHIFTING,RIDINGANDSTOPPING
NOTE
Alwaysstart motorcycle withthe gear in neutral position.
When the engine speed decreases or while climbing a gradient or running at a reduced speed, shift to the appropriate
lower gear toprevent theengine fromstalling or straining topull.
n Always shift to lower gears asappropriate whenever slowingdown tostop thevehicle.
n Shift gearsto neutral position just before bringingthe vehicle toa complete stop always.
n Close throttle fullyand release the clutchlever slowlyensuringthemotorcycle isinneutral positionand neutral lamp
is glowing.
n Stop the motorcycle in a safe place, turn “OFF” ignition and switch “OFF” engine kill switch.
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n Selecta firm,flat surface.
n Hold handle bar firmly in a straight position.
n Lower centre stand, suchthat, boththe legsof thestand are restingona firmground.
n Applypressureonthefulcrumleveronthecentrestandandpullthemotorcyclebackward.
n Lockthesteeringandensurethehandlebarislocked firmly beforeremovingthekeyfrom
the ignitionbarrel.
PARKING MOTORCYCLE ON CENTRE STAND
PARKING
61
PARKING
WARNING
Ensure bothstandsare fullyretracted before riding the motorcycle.
Please exerciseextremecarewhileparking andensure it isparked ona firmand flat surfacetoavoid themotorcyclefrom
falling over and causing injury to you or to others and damage tothe motorcycle parts.
PARKING MOTORCYCLE ON SIDE STAND
n Select a firm,flat surface.
n Extend side stand. Tilt the motorcycle to the left side, till it is supported firmly on the
ground.
62
TOOLS KIT
The tool kit islocated in the right side panel of the motorcycle.
S.No. Description Qty.
1. C Spanner 1
2. Allen Key 6mm 1
3. Allen Key 5mm 1
4. Allen Key 4mm 1
5. ExtensionTube 1
6. Ring Spanner 24 x 14 Combination 1
7. Screwdriver 06 x160 1
8. Double End Spanner 10 x12 2
63
MINORMAINTENANCETIPS
The following simple maintenance activities will help maintaining your motorcycle. However, for an complete
maintenance,we recommend youto get in touch witha Royal Enfield Authorised Service Centre.
HAND LEVERS, CENTRE AND SIDE STAND PIVOTS
n Cleanthe pivot pointsand ensure theyare free of anydirt, grime,rust, etc.
n Lubricate thepivots.
NOTE
Wipe off theexcess lubricant to prevent dirt and grime fromaccumulating.
64
DRIVE CHAIN
n Spraydrive chainwith recommended chaincleaningsolvent while simultane-
ouslyrotating rear wheel.
n Ensure the drive chain has been sufficiently and completelycovered with the
cleaning solvent. If necessaryuse asuitable brushtoremovehard depositsfrom
the chain.
n Wait fora few minutesand cleanthechainthoroughlyfromanydirt,grime,etc.
n Rotate rear wheel slowly and simultaneously apply recommended chain
lubricant onthe chain links.
n
MINORMAINTENANCETIPS
Wipe off excess chain lubricant after a few minutes with a clean cloth.
65
MINORMAINTENANCETIPS
CAUTION
Use of wrong grade or spuriousoilscanseriously affect motorcycle performance and damage to movingparts. DO NOT
over fill beyond the “MAX” level or allow oil level to drop belowthe “MIN” level.
OIL LEVEL INSPECTION
n Ensure motorcycle is inupright positionona firmandflat surfaceonits centre
stand.
n Start theengine and allowit toruninidlingrpm for about 2 minute and switch
off the ignition.
n Wait for 2 minute for the oil to settle down and check oil level through the
window on RH cover of the engine.
n The level iscorrect onlyif the oil is found betweenthe “MIN” and “MAX” marksonthe cover RH.
n If necessarytop up ONLY withrecommended engine oil till the level isbetweenthe “MIN” and “MAX” markings.
66
n Remove the engine oil filler cap for adding the engine oil.
n Place a clean tray under the engine oil magnetic drain plug. Remove it along
withthe washer todrain oil completelyfrom the engine.
WARNING
DO NOT spill theengine oil. Store used oil in a separate container anddispose it.
Avoid skin or body contact with the oil. Promptly wash the affected areas with
soap and water till it is cleaned thoroughly.
MINORMAINTENANCETIPS
67
n Place a container under engine oil drainbolt.
n Gentlyapply thread sealant ondrain plug thread.
n Insert the drain plug bolt along withnew washer.
n
n
Tighten the drain plug bolt to 35 Nm.
n Close engine oil filler cap.
n Start and warmup enginefor 2 to 3minutesand thenturnit off.Check oil level
MINORMAINTENANCETIPS
NOTE
through oil level window.
Ensure the engineoilisdrained completely. Drain theoil completely and to avoid oil spilling.
ENGINE OIL FILLING
CAUTION
DO NOT over fill engine oil as excess oil will spill over through the crankcase
breathing systemand clog the air filter.
Refill the engine oil recommended level.
68
CLEANING SPARK PLUG AND ADJUSTING GAP
SPARK PLUG
n Disconnect spark plugcaps fromthe spark plugs.
n Locate spark plug spanner on the spark plug, loosen spark plug and remove it from
cylinder head.
n Checksparkplug for carbondepositsand centre electrodesfor unevenwear.
n Clean spark plug by positioning it in a spark plug cleaning machine.
MINORMAINTENANCETIPS
Gap 0.7 to 0.8 mm.
n Remove spark plugfrom the cleaning machine,checkand set electrode gap between 0.7 to 0.8 mm.
n Position spark plug in the spark plug testing machine and check for proper functioning of the spark plug.
n Always replacespark plugs ONLY as per recommended specification.
n Apply a thin film of “anti seize” on the sparkplug mounting and threadsfix the spark plug by hand tightening.
n Tighten spark plug to torque 10 to15 Nm by using a spark plug spanner.
69
MINORMAINTENANCETIPS
BRAKE FLUID FRONT AND REAR
n Ensure motorcycle isupright ona firmflat surface onitscentre stand.
n Check brake fluid level inthewindowonfront and rear reservoirs.
n The level iscorrect if the oillevel isbetweenthe “MIN” and “MAX” marks.
n Openthe reservoir cover and remove diaphragmcarefullytotop up
the brakefluid.
CAUTION
Brake fluidishighlycorrosiveand cancause damage to painted parts.Please ensure that brake fluid doesnot spillonany
part of the motorcycle.Inthe event of a spill,please clean the area immediately witha soft wet clothtoavoid damageto
theaffected part.
DO NOT mix different brake fluid grades. Use ONLY DOT 4 Brake fluid.
Front Brake Rear Brake
n Top up only withDOT 4 brake fluiduntill level isbetween“MIN” and “MAX” marksin the reservoir.
n Replace diaphragmcorrectly and closecover firmly.
n Wipe off any excess / spilled brake fluid immediately with aclean cloth.
70
MINORMAINTENANCETIPS
INSPECTION OF TYRES AND WHEELS
n Checkandremovestone,splinters,nailsorotherparticlesembeddedinthetyretreads.
n Periodicallyinspect wheelsfor spokes damageandwheel rimfor wobblingor runout.
n Checkuniformseatingofthetyrebeadingontherimwheneverthetyreisreassembled.
n Useonlyrecommendedtyresandtubes,inflatedtocorrectairpressureasgivenbelow.
n Inspect the tyresperiodicallyfor tread wear, cracksand cuts.
Minimum tread depth :
Front tyre : 1 mm Rear tyre :2 mm
Front Rear
Solo 32 psi/2.20 kg/cm 36 psi/2.53 kg/cm
With Pillion 32 psi/2.20 kg/cm 39 psi/2.74 kg/cm
71
MINORMAINTENANCETIPS
FRONT WHEEL REMOVAL
n Ensure motorcycle is upright on a firmand flat surface.
n Place a woodenblock onthe front end of engine tosupport the motorcycle and ensure
front wheel is off the ground by minimum 2 inches.
n Fromwiring harness RH side disconnect the speedo drive coupler.
n Loosen thepinchbolt on the front fork bottomright side.
n Remove the axle nut alongwithwasher,holdthe wheel axle onthe right side and loosen
hex nut on theleft completely.
n Remove axle nut and washer from wheel axle.
72
MINORMAINTENANCETIPS
n Placea 4mmthickwoodenpieceor cardboard sheet betweenthebrakepadstoavoidpadsactivationintheevent the
front brakelever isaccidently pressed.
n Take care not to damage the front brake disc or toneringasit will affect the brakingsystemand ABS.
n Tap and remove the front wheel spindle, gently tap axle from left side while supporting
wheel at the bottomthenremove axle fromthe right side.
Do not pressthe brake lever when front wheel is removed as this will result in the brake pads coming too far out of the
brake caliper.
CAUTION
Take care to secure the wheel spacers and speed sensor while removing the axle from the
forks.
n Slide out the front wheel fromtheforks.
CAUTION
73
FRONT WHEEL REASSEMBLY
n Remove the woodenpiece / cardboard sheet placed betweenthe brake pads
n Locate speedodrive toitscorrect positiononthe right side.
n Locate stepped spacer tothe wheel hub onleft side.
n Insert thewheelalongwithspeedodriveandspacer betweenthe forkends.Ensure the
brake discislocated between thebrake pads.
n Supportfront wheel at thebottomand ensurethemountingholesarealigned toinsert
thewheel axlealong theright side fork end. Gentlytapaxleintowheeltillthethreaded
portionof axle isfullyvisibleon the left side fork end.
n Assemble washer and nut on axle.
n Hold the wheel axle firmly on right side and tighten axle nut firmly on left side to a
torque of 70Nm.
n Tighten pinchbolt completely onforkend to atorque of 25 Nm.
MINORMAINTENANCETIPS
74
n Rotate wheel to checkfor smoothrotation.
n Connect the speedowire coupler and check for proper working of speedometer.
n Pressbrakelever and check frontbrake efficiency.
CAUTION
Please exercise utmost caution while reassembling the frontwheel onthe motorcycle.
please ensure the wheel isfitted correctlybefore attempting to ride the motorcycle.
Failure to do so may result in the motrocycel not performing correctly, may lead to an accident causing injury to you /
other road usersand maylead toloss of life.
MINORMAINTENANCETIPS
75
MINORMAINTENANCETIPS
REAR WHEEL REMOVAL
n Ensure motorcycle isupright ona firmand flat surface withthe rear wheel atleast
6 inchesraised above from thesurface.
n Observe and markthe alignment indexes onboth chain adjuster on left and right
side swing arm.
n Loosenthe locknutsand adjusternutsfullyonthe left and right side chainadjuster.
76
n Hold wheel spindle onleft side firmly and loosen hex nut on right side.
n Remove the nut and washer from the wheel spindle.
n Push rear wheel fully into the swing arm.
n Supportrear wheelfrombottomandpulloutwheel spindle fromtheleftside swing
arm.
n Release the brake hose gently and remove caliper assembly from swing arm on
MINORMAINTENANCETIPS
right side.
n Ensure brake hose doesnot get damaged or kinked while removing.
n Support caliper assembly suitably and away from swing arm.
n Releasethechainfromthesprocketand ensure it doesnot getjammedordamaged
when removingrear wheel.
n Remove supportfromwheelbottomand gentlyslideoutrear wheelfromtheswing
armwithrear sprocket, brake disc andspacers.
CAUTION
77
MINORMAINTENANCETIPS
Donotpresstherearbrake pedalwhentherearwheel isbeingremovedasthiswillcause thebrake padsto dislocate from
thebrakecaliper.
CAUTION
n Place a 4 mm thick wooden piece or cardboard sheet between the brake
pads to avoid activation of brake pads if rear brake pedal is accidentally
pressed.
DONOT pull up the rear brake pedal tolift or raise the motorcycle for anyreason.
CAUTION
78
REAR WHEEL REASSEMBLY
n Ensurethatthelongsteppedspacerislocatedonthebrakediscsideandtheshortspacer
islocated onthe sprocket sideof the wheel hub firmly.
n Ensure that thechain adjuster are located properlyinside theswing armleft and right
sides.
n Locate caliper assembly on the tab along theswing arm right side.
n Locate rear wheelwiththe sprocket totheleft sideensuring the brake discin-between
the brake pads onright side.
n Lift up the rear wheel and ensure that theslotsintheswingarm brake caliper bracket
holesin chainadjustersandthe centrehole in the hub are aligned.
n Support rear wheel suitably andinsert rearwheel spindle alongthe leftside swingarm
intothe wheel hub.
n Ensure thatthelongsteppedspacer islocated alongthebrakesideandthe short spacer
MINORMAINTENANCETIPS
is located along the sprocket side on the wheel hub.
79
MINORMAINTENANCETIPS
n Tapspindlegentlyintowheel hubslot till the threadsare completelyvisibleonthe right
side.
n Assemble the drivechain on the sprocket andensure it isseated correctly.
n Checkfor free and smoothrotationof the rear wheel.
n Assemble washer and hex nut on wheel spindle on right side.
80
DO NOT TIGHTEN HEX NUT FULLY
n Tightenchain adjuster nutsonleft and right adjuster suchthat the index marksare aligned correctlyonbothsides of
the swing arm.
n Checkand ensure correct chaintension and wheel alignment.
n Hold spindle firmly onleft side and tighten hex nut onright side set torque to 70 Nm.
n Locate the brake hose inthe clips along the swing arm right side.
n Checkrear brake for proper operating efficiency.
CAUTION
Pleaseexercise utmost caution while reassembling therear wheel onthe motorcycle.
Please ensurethewheel isfitted correctly before attemptingto ride the motorcycle.
Failure todosowill result in poor performance of motorcycle whichmaylead toanaccident causinginjuryto you/ other
road usersand may lead to loss of life.
MINORMAINTENANCETIPS
81
MINORMAINTENANCETIPS
ADJUSTMENTS - CLUTCH
n Loosenthecable outer lock nut .
n Turnthe nut clockwise to reduce the playor anticlockwise toincrease thefree
play.
n Tighten lock nut after adjustment isdone.
n Check free play 2to3mmat clutchleverpivotonhandlebar end,ifdesiredfree
playisnot achieved readjust.
REAR BRAKE LIGHT
The brake light glows once youpressthebrakelever.
If brake light isnot glowing, check the brakelight switch wire for proper connection.
82
MINORMAINTENANCETIPS
DRIVE CHAIN TENSION (Free Play 20-30 mm)
Parkmotorcycle up right on a firmand flat surface.
n Ensure the motorcycle isin neutral position.
n Measure the drive chainfree playas shown.Thedrivechainfreeplayis20mm
to 30 mm.
1. If the drive chainfree playis found to be incorrect adjust as follows:
a. Loosen the axle nut of the rear wheel axle.
b. Loosen the lock nut ontheadjuster at bothend of the swingarm.
c. To reduce thefree play, tightentheadjuster nut onthe adjuster evenly.
n
83
d. To increase the free play,loosentheadjuster nutsevenly and pushtherear wheel forward.
e. Check thechainfor correct chain tension.
f. Ensure that the index marks on the adjuster and swingarmare same onbothleft and right side of the swingarm.
g. Hold spindle firmlyto the left side and tightenrear hex nut to a torque of 70 Nm.
h. Tighten the adjuster locknut using a 24mm spanner.
MINORMAINTENANCETIPS
WARNING
Chain slackness beyond 30mm will lead to chain slippage and may also cause increased wear rates to chain and
sprockets.
Maintaindrive chainslackness withinthespecified limitsat every1000 kmsinterval.
Please ensure thebothwheelsarealignedcorrectly,afteradjustingthe chainandbeforetightening therear wheelspindle
nut.
84
BATTERY AND MAINTENANCE
n The Motorcycle isprovided with 12V - 12 Ah battery.
n Thebattery must be periodicallychecked for cleanlinessand corrosionfree
MINORMAINTENANCETIPS
terminals.
NOTE
The poor contact or loose fitment of batteryterminalsmaycause ECU failure.
DISMANTLING
n Switch “OFF” the engine and remove ignition keyfrom the key barrel.
n Disconnect battery negative(- ve) terminal bolt.
85
MINORMAINTENANCETIPS
n Remove 3Nos.Hex head boltsfromtool box to access thebattery.
n Disconnect battery positive (+ve)terminal frombattery.
86
n Pull batterystrap (belt)downwards and release strap lock from battery
strap bracket.
n Loosenand remove hex flangehead screw frombatterystrap bracket.
MINORMAINTENANCETIPS
87
n Removebatterystrapbracket frombattery tray.
n Remove batteryfromtray.
MINORMAINTENANCETIPS
88
MINORMAINTENANCETIPS
WARNING
Alwaysdisconnect the black negative (-ve)batterycable first and thenthe red positive (+ve) cable while removing the
batteryconnections.
NOTE
For checking the battery voltagecontact Royal Enfield Authorised Service Centre or batteryservice centre.
89
ASSEMBLY
n Assemble batteryin totray.
n
MINORMAINTENANCETIPS
Place batterystrap bracket into batterytray.
90
n Locate and tighten flanged head screwinto batterystrap bracket.
n
MINORMAINTENANCETIPS
Pull batterystrap(belt)downwardstofixstrap lockintobatterystrap bracket.
91
n Connectbatteryred positive (+ve) terminalbolt.
n
MINORMAINTENANCETIPS
Locate and tighten3 nos. hex head boltsintotool holder.
92
NOTE
Cleanthewireterminalsfree fromcorrosion and keep the terminals coated withpetroleumjelly.
n Connect red batterynegative (-ve) terminal bolt.
MINORMAINTENANCETIPS
CAUTION
Keepthered(+ve)positiveterminal and(-ve)negativeterminal cablesfirmlyconnectedtothe respectivebatteryterminals.
Failure to do so mayresult in damage to the motorcycleelectrical system.
CAUTION
Connect the black (-ve) negative terminal after connect red (+ve) positive
terminal only.
93
MINORMAINTENANCETIPS
CHANGING ELECTRICAL COMPONENTS
HEADLAMP BULB REPLACEMENT
n Loosen the rim holdingscrew on top and take out the head lamp dome.
n Disconnect electrical connections.
n Thumb push and remove the bulb holding clamp gently.
n Remove the bulb usinga clean and soft cloth.
94
n Positionthe newbulb inside the reflector suchthat the three projections on thebulb
alignwith theslot on the reflector.
n Refit the bulb holding clamp.
n Connect the electrical connections.
n Positionhead lamp dome onto thehead lampshell and tightenthe mounting screw on
top.
NOTE
Never touchthebulb withyour fingers. Finger printswill etchthe glassand decrease bulb
life apart from causing burnsto your fingers.
MINORMAINTENANCETIPS
Always hold the bulb with gloves and clean dry cloth during handling.
95
MINORMAINTENANCETIPS
TAIL LAMP BULB
n Unlock the side panel RH.
n Remove the seat assembly by pulling seat lock cable.
n Remove the tail light cover by unscrewing its mounting
screw.
n Hold the bulb, press inside and rotate anticlockwise to
removethetail lightbulb fromitsholderusingacleancloth.
n Replace the bulb 12V 21 / 5Wusing a soft clean cloth.
n Re-assemblethetaillightinthereverseorderofdismantling
process.
96
TRAFFICATOR BULB REPLACEMENT
n Remove the screwfrom thetrafficator housing.
n Open the indicator housing.
n Remove the bulb holder with help of a screw driver.
n Removethe bulbandreplace the sameusinga softandclean
cloth.
n Refit the holder toitsproper position.
n Fix therubber gasket cover.
n
MINORMAINTENANCETIPS
Assemble the indicator housing cover.
97
MINORMAINTENANCETIPS
FUSE AND FUSE CARRIER
WARNING
Electronic Control Unit (ECU) may fail due toloose electricalconnections, loose battery terminals, etc. Hence,it isvery
important to keep all the electrical connections are intact.
n Thefuse carrier islocated under the seat.
n Unlock side panel RH.
n Release seat lock by pulling knob and remove the
seat.
98
MINI BLADE FUSE USAGE LIST
MINORMAINTENANCETIPS
Fuse ID Color Rating Remarks
Number
1 V 30 A Alternator
2 R-W 30 A Main Fuse
3 G-W 15 A Ignition Fuse-EFI
4 R 10A Signalling Fuse
5 BR 10 A Horn Fuse
WARNING
Please get the electrical system of your motorcycle checked thoroughlyand get the faults corrected immediatelyafter
experiencing any fuse failure.Failure todoso mayresult inrepeated fusefailure.
Usage of fuses other thanspecified rating will damage the complete electrical system.
Fuse ID Color Rating Remarks
Number
6 R 15 A Lighting Fuse
(Head Lamp)
7 R-W 10 A Accessory Fuse
8 R 10 A ABS Fuse
9 R-W 25 A ABS Fuse
99
CLEAN AND REFIX : EVERY 5000 kms
n Removethe screwfromthe side panel bottomside
and remove side panel.
n Removetheairfiltercoverscrewsandthentakeout
n Pulloutfilterelementandcheckfordirt. Cleanfilterelementcarefully.
MINORMAINTENANCETIPS
AIR FILTER
NOTE
Usage of highpressure compressed air is not recommended to cleanair filter element.
Fitment of air filter element isinthe reverse order of removal process.
airfilterboxcover.
100
LONGTRIPPRECAUTIONS
CHECKS PRIOR TO THE COMMENCEMENT OF A LONG JOURNEY
n Service themotorcycle at Royal Enfield Authorised ServiceCentre.
n Ensure sufficient quantityof fuel isalwaysavailable inthe fuel tankfor the journeyplanned.
n Checkandcorrect tyrepressureifnecessary.
CHECKS AFTER EVERY 1500 KMS OF RUN
n Anyloosefasteners.
n Conditionof the tyres.
n Correct oillevel inengine.
n Working of all lights and horn.
n Proper drive chaintension.
n Clutchcable free play.
101
LONGTRIPPRECAUTIONS
ITEMS TO BE CARRIED
n Tools kit.
n Bulbsfor headlight, trafficator light and mini blade fuses (10 and 15 A).
n Accelerator and clutchcable.
n Sparkplug, spark plug cap.
n Sparetubes.
102
PRECAUTIONS
n Remove ignition keyand seal theignitionkey barrel slot usingadhesivetape.
n Coverthesilencer tailpipe,hornandcontrolswitcheswithsuitableplasticbagsand tieitfirmlytopreventwater entry.
n Wash the motorcycle only when the engine is in cold condition.
n Do not remove side panel while washingto avoid water entry.
n Brushengine area witha recommend noncorrosive solvent toremove dirt or grease.
n Use lowpressure water jet toclean.
n Neverspraywaterwithgreatforceonheadlamp,meter/clusterunit,flasher lights,front andrearwheelhubs,electrical
connections and wires, control cables,EFIcomponents, sparkplug, battery, side panels.
n Donot applyanycorrosive solvent onpainted surfacesor rubber parts.
n Use lukewarmwater and mild detergent onthe painted componentstoremove dirt, etc.
n
WASHINGPROCEDURE
Cleanmotorcycle thoroughlywith plainwater toremove the detergent.
103
AFTER WASHING
n Ensure, the motorcycle is thoroughlydry by wipingwith a cleansoft lint free absorbent cloth or chamoisleather.
n Remove all adhesive tapes.
n Lubricate controlcables, pivotsfor footrest, side stand, centre stand,brakeandgear shifter linkages,drive chainetc.
with lube oil.
n Polish the painted and plated surfaces using recommended automobile polishing wax.
n Start the engine and allowtorun at an idling speed for a fewminutes to warm up engine.
n
WASHINGPROCEDURE
Drive the motorcycle slowly, applyboththebrakesintermittentlytodryup thewater inbrake pads.
n If possible, use compressed air and blow off water particles from the obscure areas of the motorcycle, electrical
connectionsetc.
104
In-case your motorcycle is not going to be used for a month or more,the following precautions should be taken.
n Get the motorcycle serviced througha RoyalEnfield Authorised Service Centre.
n Drainthe fuel completelyfromthe fuel tank and induction system.
n Remove spark plug. Pour in about 5ml of clean engine oil through spark plug hole. Close the hole and crank engine
several timesand refit sparkplug.
n Clean drive chain thoroughly and apply Royal Enfield recommended chain lubricant.
n Wipe off excesslubricant after 5 minutes of application.
n Removebatteryfromthe motorcycle.Cleantheterminalstofreefromcorrosionandapplypetroleumjellytoterminals
and cover boththemusing a plastic sheet.
n Storethebatteryina cool,dry andwell ventilated place.
n Cover the silencer withsuitable bagsto prevent moisture entry. Set the motorcycleon itscentre stand.
n Applyanti rust solutionson all plated parts.Take care not toapply this solutiononchrome, rubber or painted parts.
Storemotorcycle ina cleancovered area free of moisture and dust.
n For re-use after storage, it ispreferable to get the motorcycleprepared through a Royal Enfield Authorised Service
STORAGEPRECAUTIONS
Centre to ensure the motorcycle isrestored toitspeak operatingconditions.
105
TROUBLESHOOTING
WARNING
Thetrouble shootingsectionof thisOwner’sManual isintended solelyasa guide for diagnosingproblems. Carefully read
the appropriatesectionsof thismanualbeforeperforminganywork,repair and maintenanceoperationsnot listed inthis
Owner’sManualshouldbeperformedbyyourRoyalEnfieldAuthorisedServiceCentreonly.Improperrepair /maintenance
willresult in the motorcycle not functioning properlyor serious injury.
CAUSES REMEDIES
*Contact Royal Enfield Authorised ServiceCentre
I. ENGINE FAILS TO START
1) Ignition switch in “OFF” position Turn Ignition switch “ON”.
2) Engine kill switch in “OFF” position Kill switch to “ON” position.
WARNING
Please get the electrical system of your motorcycle checked thoroughly and get thefaults corrected immediatelyafter
experiencing anyfusefailure.Failure tocomply can result intorepeated fuse failures.
Usage of fusesother thanspecified rating will damage the complete electrical system.
106
TROUBLESHOOTING
CAUSES REMEDIES
3) No fuel in fuel tank Refill fuel.
4) Battery low voltage indicator is glowing Check battery for voltage/ chargingcircuit.
continuously
5) Engine Malfunction indciator is glowing Get the motorcycle inspected through a Royal Enfield Authorised
continuously ServiceCentre.
6) Sparkplug cap / lead not connected Fix cap / lead firmly.
7) Spark plug electrode dirty /fouled Cleansparkplug
8) Sparkplug insulationcracked Replace sparkplug.
9) Main or EFI fuse blown out Replace with new fuse.
*Contact Royal Enfield Authorised ServiceCentre
107
TROUBLESHOOTING
CAUSES REMEDIES
II. ENGINE MISFIRING
1) Loosespark plug cap Fix cap firmly.
2) Sparkplug fouled Cleanspark plug or non specified heat range plug.
3) Any sensor loose connections *CheckMAPorEOTorTPSsensorwiring/couplerlooseconnections.
4) Water infuel tank * Clean fuel tank. Fill tank with fresh petrol.
5) Engine startsbut shutsof immediately Check if the MIL indicator continuously is glowing; If yes*
6) Engine misfires and runs erratically Check if the MIL indicator continuously is glowing; If yes*
*Contact Royal Enfield Authorised ServiceCentre
108
III. POOR PICKUP
1) Brake pedal adjusted too tight *Re-adjust properly, refer to respective section.
2) Choked air filter Clean/Replace airfilter.
3) Drive chain tigh *Re-adjust properly.
4) Under inflated tyres *Inflatetocorrectpressure.
5) Accelerator cablefree playexcessive Adjust accelerator cable free play.
6) Clutch slipping *Adjust clutchcable free play.
7) Faulty fuel supply, fuelpump, *Remove fuel pump and clean.
filter / injector blocked
TROUBLESHOOTING
CAUSES REMEDIES
8) Poor pickup Checkif the MIL indicator is glowing; If yes*
*Contact Royal Enfield Authorised ServiceCentre
109
TROUBLESHOOTING
CAUSES REMEDIES
*Contact Royal Enfield Authorised ServiceCentre
IV. ENGINE OVERHEATING
1) Lowengine oil level Check and top-up if necessary.
2) Clutch slipping *Check andcorrect.
3) Cylinder fins not clogged Cleanthecylinder finsat regular intervals.
V. EXCESSIVE FUEL CONSUMPTION
1) Under inflated tyres Inflatetocorrect pressure.
2) Choked air filter Clean/ Replace.
3) Fuel leakage *Check and rectify,tankfloat unit,drainpipe,breather pipe,
fuel line, pump, EVAP system.
110
TROUBLESHOOTING
CAUSES REMEDIES
*Contact Royal Enfield Authorised ServiceCentre
VI. BRAKES POOR
1) Brake pad worn/ Unevenwear *Replace brake pads.
2) Oil / grease on disc. *Cleanand refit.
3) Spongybrake *Fill brake fluid and performbrake bleeding.
VII. MOTORCYCLE WOBBLES
1) Under inflated tyres Inflatetocorrect pressure.
2) Loose/ Brokenspokes * Tighten/ Replace spokes.
3) Wheels misaligned *Ensure proper alignment.
4) Wheel rim runout * Rectify.
5) Tyres not fitted correctly *Refit tyrescorrectly.
111
VIII. ELECTRICALS
Bulbs do not glow
1) Bulb fused * Replace bulb.
2) Fuse blown *Check and replace fuse.
3) Loose / improper connection * Check and correct.
Horn not working
1) Fuse blown Checkandcorrect.
2) Loose connections Check andcorrect.
Trafficators not working
1) Loose/ improper connections Checkandcorrect.
TROUBLESHOOTING
CAUSES REMEDIES
2) Bulb fused Replace.
*Contact Royal Enfield Authorised ServiceCentre
112
IX. ELECTRONIC FUEL INJECTION (EFI)
Malfunctioning indicator lamp (MIL) glowing continuously
1) Sensor coupler loose connection *Check for all EFI sensor coupler loose connection and correct them.
2) Any EFI sensor failure *Checkand replace thesame.
X. ABS (ANTI LOCK BRAKING SYSTEM)
TROUBLESHOOTING
CAUSES REMEDIES
1) ABS indicator continuously “ON” Take the vehicle to servicecentrefor diagnosis.
*Contact Royal Enfield Authorised ServiceCentre
MAIN
CIRCUIT
DIAGRAM
PERIODICAL MAINTENANCE
116
Sl.
No.
DESCRIPTION PERIODIC MAINTENANCE
I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean
(#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms.
(**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms.
1 Engine Oil (#)
2 Engineoil filterelement (#) R R R R R R
3 Inlet and Exhaust valveclearance (**) I I I I I I
4 Spark plug I I I I R I I I R I I
5 HT lead for crack I I I I I I I I I I I
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Months
Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30
Check level at every 1000 Kms or earlier and top up as required
R R R R R R
The maintenance schedule detailed here will help you to maintain your interceptor INT 650 motorcycle meticulously to get a
long trouble free service. The schedule provided herein is based upon an average riding conditions and indicates the km/miles at
which regular inspections, adjustments, replacements and lubrications are to be carried out. The frequency of the maintenance
must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dust environment.
Contact the nearest Royal Enfield Authorised Service Centre for expert advice and to carry out the required maintenance.
1.5 6 12 18 24 30 36 42 48 54 60
117
PERIODICALMAINTENANCE
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30
Sl.
No.
DESCRIPTION PERIODIC MAINTENANCE
(#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms.
(**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms.
6 Rubber hose, AirfiltertoThrottlebody I I I I I I I I I I I
7 Rubberhose, Inlet manifold/ Adaptor I I I I I I I I I I I
8 EvaporativeEmissionEquipmentrubberhoses I I I I I I I I I I I
9 Fuel filter- External R R
10 Airfilterelement
C C R C R C R C R C R
Clean/replace more frequently ifoperated in dusty condition
11 Vent Pipeunder airfilter box I I I I I I I I I I
12 Hose - Secondary Air I I I I I I I I I I I
13 Acceleratorand Throttlepulley cables free play
14 Clutch Cable/ leverfree play Adjust every 1000 Kms or earlier as required
15 Hand levers pivot point Lubricate every 1000 Kms or earlier as required
I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean
A A A A A A A A A A A
Months 1.5 6 12 18 24 30 36 42 48 54 60
118
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30
Sl.
No.
DESCRIPTION
(#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms.
(**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms.
16 Brake pads - Front and Rear
17 Disc Brake fluid level - Front and Rear
18 Rear brakepedal and Gearchangepedal pivot
19 Brake hose and Banjo Bolt - Front and Rear
20 Front Fork oil leak
I I I I I I I I I I I
21 Steering tapper roller bearing Play I I I I I I I I I I I
22 Rear Wheel Drive Chain
Lubricateand Adjust every 1000 Kms / Clean, Lubricate and
Adjust every serviceor earlier as required
23 RearwheelCush rubbers I I
PERIODICALMAINTENANCE
PERIODIC MAINTENANCE
I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean
I I I I I I I I I I I
I I I I I I I I I I I
L L L L L L L L L L L
I I I I I I I I I I I
I I I I R I I I R I I
24 Spokes tightness / Wheel rimrun outfront andrear
Replace oil at every 60000 kms or any work carried out whichever is earlier
Months 1.5 6 12 18 24 30 36 42 48 54 60
119
PERIODICALMAINTENANCE
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30
NOTE
Sl.
No.
25 Batteryterminals (applypetroleum jelly) C C C C C C C C C C C
26 Battery electolytelevels (Notapplicable forsealed battery) I I I I I I I I I I I
27 Earth wireeyelet tightness I I I I I
28 Tyre wearpattern front and rear
29 Pivot-SideStand, Centre Stand L L L L L L L L L L L
30 RiderandPillion Footrest pivot
31 Allmounting fastenersin vehiclefortightness I I I I I I I I I I I
(#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms.
(**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms.
PERIODIC MAINTENANCE
I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean
I I I I I I I I I I I
L L L L L L L L L L L
For Maintenance after 50,000 Kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorised Dealer / Service
Centre.
DESCRIPTION
Months 1.5 6 12 18 24 30 36 42 48 54 60
kms/
miles
Royal Enfield
Authorised Dealer
120
121
SERVICE MAINTENANCE RECORD
S.No. Date Brief detailsof work / service
9.
10.
11.
12.
13.
14.
15.
16.
Job Card
No.
Royal Enfield
Authorised Dealer
kms/
miles
122
SERVICE MAINTENANCE RECORD
S.No. Date Brief detailsof work / service
17.
18.
19.
20.
21.
22.
23.
24.
Job Card
No.
Royal Enfield
Authorised Dealer
kms/
miles
123
WARRANTYTERMSANDCONDITIONS
Royal Enfield warrants its motorcycle to be free from manufacturing and materials defects, under normal use subject to the
following conditions.
1. Warranty shall bein force until the expiry of a period of 36monthsfrom thefirst dateofsale to the first customerand to any
subsequent owners for thebalanceof theremaining period, until expiry of 36months fromthedate of first sale/registration
of the motorcycle.
2. In order to effect Warranty, it is a prerequisite that the maintenance schedule prescribed by Royal Enfield in this Owner’s
manual and warranty repairs if any, has been carried out at the AuthorisedDistributor’s service facility ORat their Authorised
dealership’s service facility.
3. Record of all the regular servicesand periodical maintenance that have been carried out, along with proof of servicehistory
will be required to be verified by the Authorised Distributor’s service facility OR their Authorised dealership’s service facility
prior to carrying out a warranty service.
4. Proof of Ownership, in the form of Sales Registration OR Proof of Purchase documentation of the motorcycle, clearly
mentioning the Engine and VIN numbers, must be provided to the Distributor’s service facility OR their Authorised
dealership’s service facility.
5. During the warranty period, Royal Enfield’s obligation is limited to repair or replacing free of charge, such part or parts of
the motorcycle which in examination shall be deemed defective in the opinion of Royal Enfield and/or their distributors/
authorised dealers. Such defective part/s, which has been replaced, shall become the property of Royal Enfield.
124
6. Cost of Consumables like fuel, oils etc, labour, shipping charges of replacement parts for any warranty replacement are
chargeable to the customer.
7. Warranty is not applicable for the following parts:
n Normal ageing of parts like rubber parts, tyres and tubes, hand grips, glass, plastic, soft items like seat rexene, cushion etc.
n Dullness of chrome plated parts, discolourisation of chromed exhaust pipe / silencer, buffed parts, painted surfaces etc.
n Normal wear and tear items such as control cables, brake pads/ shoes, clutch plates etc.
n Electrical items like bulbs, wiring harness, switches, battery, fuses, electric start motor etc.
WARRANTYTERMSANDCONDITIONS
8. Warranty will become void under the following conditions:
n Damages due to lack of proper maintenance, periodicservices not carried out asper Royal Enfield recommendation etc.
n Damages caused by any unauthorised repairs carried out in any part of the motorcycle.
n Failures occurred due to use of non recommended grade lubricants, fuel or improper level.
n Use of non genuine Royal Enfield parts.
n Damages caused due to unauthorised alterations to any part of the motorcycle.
n Use of accessories not supplied by Royal Enfield.
n Motorcycle fitted with side cars.
125
WARRANTYTERMSANDCONDITIONS
n Motorcycle used in rallies, off road, dirt track, races etc.
n Motorcycle involved in accidents, collisions etc.
n Damages that occur due to extreme operating conditions beyond the limitation or specifications as given by Royal
Enfield, such as maximum load carrying capacity, engine speed etc.
n Damages that occur due to long/improper storage, transportation of motorcycle etc.
9. Royal Enfield reserves the right to finally decide on all warranty claims.
10. RoyalEnfieldreservestheright tomakechangesinthemotorcyclewithout anyobligation toinstallthesechangesonpreviously
sold motorcycle.
11. Royal Enfield authorised distributors and /or their dealers are independently owned and operated. They may hence deal
with other aftermarket products for which Royal Enfield is not responsible for the performance, safety, quality, reliability
and suitability of such products. Defects, if any in such parts OR that may arise in the motorcycle due to use of such parts is
not liable to be covered by Royal Enfield and may render this warranty void.
12. There is no other express OR implied warranty in the motorcycle. Any implied warranty of merchantability or fitness is
limited to the duration of this warranty.
13. To the fullest extent allowed by law, Royal Enfield and its authorised distributors and/or dealers shall not be liable for loss
of use, inconvenience, loss of time, commercial losses or other incidental or consequential damages.
126
EMISSIONWARRANTY
Incompliance withthe provisionsof Rule115(2) of theCentralMotor Motorcycle Rules, 1989, Royal Enfield certifiesthat
the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its
range of motorcycle, in normal use to which it may be subjected to.
Royal Enfield furtherwarrantsthat if onexaminationbyitsRoyalEnfield Authorised Service Centre,the motorcyclefails
tomeet the specified emissionstandards, thenthe Authorised Service Centreshalltakenecessarycorrective measures
and shall, at itssole discretion, repair or replacefree of charge componentsof the emission control system tomeet the
required emissionstandards.
The method/s of examination todetermine thewarranty conditionsof the emission warranty related componentswill
be at the sole discretion of Royal Enfield and / or our Authorised Service Centre and results of suchexamination will be
final andbinding. If onexamination the warrantyconditions of thepart/s is/are not established, Royal Enfield willhave
the right tochargeall,or partof the cost of suchexamination to the customer inaddition tothecost of the components.
This emission warranty is valid for 30,000 Kms / 3 years from the date of first sale whichever earlier, to the first
customer and is in addition to and parallel to the warranty policy, conditions and obligations laid down in the Owner’s
Manual.
127
In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge the
component/sasrequired.However,theconsumableslikefuel,lubricants,solvents,etcshallbechargeabletothecustomer
as per actuals.
Incaseanyofthecomponentscoveredunderemissionwarranty ortheassociatedpartsarenotindependentlyreplaceable.
Royal Enfield will have the solediscretiontoreplace eitherthe entire assemblyor partsof the assembly throughsuitable
repairs.
Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace any part, in
additiontotherepair orreplacement of thecomponentscoveredunder emissionwarranty,to establishcompliance toin-
use emissionstandards. Suchrepairs / replacementswill be chargeable to the customer.
All parts removed for replacement under warranty will become theproperty of Royal Enfield.
Royal Enfield will not be responsible for the cost of transportationof the motorcycle tothe nearest Authorised Service
Centre OR for any loss due to nonavailability of the motorcycle during the period of examination and repairs by Royal
EMISSIONWARRANTY
Enfield and /or their Authorised Service Centre.
128
EMISSIONWARRANTY
Royal Enfield willnot beresponsible for anypenaltiesthatmaybe chargedby statuatoryauthoritiesonaccountof failure
to comply with the in-use emission standards.
The cost incurred tocheck emission of the motorcycle will havetobe bornebythe customer.
Emissionwarrantywillbeapplicableirrespective of thechange of ownershipofthemotorcycleprovidedall theconditions
as laid downin this document are met fromthe date of original sale of the motorcycle.
THE WARRANTY SHALL APPLY IF THE CUSTOMER
n Observes all the important instructions and anyother precautions listed in theowner’smanual.
n Under all circumstances uses lubricants and fuel asrecommended by Royal Enfield.
n Regularly obtainsand carries out maintenanceinaccordance withRoyal Enfield guidelines and enters the details in
the Log book.
n Immediatelyapproachesthenearest RE Authorised Dealer /Service Centreupondiscovery of failureto comply with
the emissionstandard inspite of having maintained and used the motorcycle inaccordance withthe instructionsin
the owner’smanual and having carried out suchrepairsand adjustments asmaybe required witha viewtoestablish
such compliance.
129
EMISSIONWARRANTY
n Production of a valid Pollution Under Control Certificate is necessary to claim Emission Warranty.
n Producesthe owner’s manual and Log book for verificationdetails.
n Producesreceiptscoveringmaintenance ofthemotorcycleisspecified intheowner’smanualfromthe date of original
purchase of the motorcycle.
n Produces valid certificate of Insurance and R TORegistration Certificate (R.C.Book).
THE EMISSION WARRANTY SHALL NOT APPLY IF
n A valid “Pollution under control” certificate isnot produced.
n Themotorcycleisnot serviced by RE Authorised Dealer /Service Centre asper theservice schedule described inthe
maintenance chart.
n The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenanceor hasmet with an
accident.
130
EMISSIONWARRANTY
n Replacement partsnot specified and approved byRoyal Enfield havebeenused.
n The motorcycle,orpartsthere of,hasbeenaltered,tampered withor modifiedorreplacedinanunauthorisedmanner.
n The odometer isnot functioningor theodometer and / or itsreadinghas beenchanged / tampered with, sothat the
actual distance covered cannot be readily determined.
n The motorcyclehasbeen used for competitions, racesand rallies or for the purpose of establishingrecords.
n On examination by Royal Enfield or its Authorised Dealer / Service Centre, if the motorcycle shows that any of the
conditions stipulated in the Owner’s manual with regard to use and maintenance have beenviolated.
n The motorcyclehasbeen runon adulterated / leaded fuel or lubricant other thanthose specified by Royal Enfield in
the Owner’smanual or anyother document given tothe customer at the time of sale of the motorcycle.
n The emission related components aretampered with.
n All service and partsrelated billsand vouchers incurred duringthe tenureof the emissionwarranty isnot produced.
n All maintenance activitiescarried out onthemotorcycle during the tenure of theemissionwarrantyare not entered
in the log book.
131
TIPS TO BE ON THE RIGHT SIDE OF LAW
n Always get your motorcycle checked to meet the emission regulations through an authorised emission checking
centre.
n Always carry a valid "Pollution Under Control" certificate with you, as and if applicable by law.
TIPS TO REDUCE POLLUTION
n Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal Enfield
AuthorisedServiceCentre.
n Use only Unleaded petrol (91 RON or higher) from reputed fuel pumps.
n Ensure thefuel usedisnot adulterated.
n Use correct spark plug asrecommended in the owner’s manual.
n
EMISSIONWARRANTY
Use lubricants asper recommendationsgiven on grade / brand in the owner’s manual.
132
EVAPORATIVEEMISSIONCONTROLSYSTEMWARRANTY
The following warranty appliesto the evaporative emission control system.
Royal Enfield Motorswarrantsthe first owner and eachsubsequent owner,that thismotorcycle isdesigned and built so
astoconform,atthe timeofsale,withapplicable regulationsspecifiedbytheevaporativeemissioncontrolsystemrelated
partsfitted to thismotorcycle are free fromdefectsinmaterialsand workmanship whichmaycause this motorcycle not
tomeet applicable regulations period of 24 Months fromthe date of first use of the motorcycle.
The Warranty periodshallbegineitheronthedatethemotorcycleisdeliveredtothe first retail purchaserORfromthefirst
date the motorcycle isused asa demonstrator OR asa display and/or trialmotorcycle.
THE FOLLOWING ARE NOT COVERED BY THE EVAPORATIVE EMISSION CONTROL SYSTEM
WARRANTY
1. Failureswhichmayarise asa result of misuse,alterations, accidentsOR nonperformance of routine maintenance,as
specified in the Owner’s Manual.
2. Replacing, removing OR modifying any portion of the EVAPORATIVE EMISSION CONTROL SYSTEM (consisting of
fuel tank,fuel tankcap, canister,purgevalve, throttle body,vapor hoses,fuel hoses and hose connectors)withparts
not certified byRoyal Enfield.
133
EVAPORATIVEEMISSIONCONTROLSYSTEMWARRANTY
3. Lossof time, inconvenience, lossof motorcycle use or anyother consequential loss or damages.
4. Any motorcycle inwhichthe Odometer hasbeentamperedwithOR the speedo cablehasbeen disconnected for any
reason OR isbrokenand not replaced immediately, due to whichthe exact distance covered cannot be determined.
5. Normal aging of partssuch asfuel hoses, vapor hoses, gasketsand rubber components.
RECOMMENDATIONS FOR REQUIRED MAINTENANCE
It is recommended that the routine maintenance of the motorcycle be carried out at specified intervals and any
maintenance to the evaporative emission control systems should be performed only by an Authorised Royal Enfield
Service Centre and usingonly genuine Royal Enfield spareparts.
134
ENVIRONMENTCARE
BEAN ENVIRONMENTALLY CONSCIOUS RIDER
You’veriddenthroughsome beautiful placeson your Royal Enfield.Won’t youlike tokeep themthatway? Here are some
tipsto help youkeep those places unspoilt so that otherscan enjoythemtoo:
ENGINE OIL
While your liquid waste like engine oil, gasoline,coolant and other cleaningsolventsneed tobe regularlyreplaced,what
happens to them? Make sure they are not dumped in the soil, down the sewers, drains, lakesor rivers around you. The
simplest wayto doit istohave themdrained into a container whichyou canhand over toyour local recyclingagent or at
yournearest Royal Enfield Authorised Service Centre. Theywill followtheguidelineslaid downbythelocalauthoritiesto
get rid of it.
BATTERY
IfyourRoyalEnfield’sbatteryneedstobereplaced,handitovertoanauthorisedrecyclingagentorRoyalEnfieldAuthorised
ServiceCentre.Theywillfollowtheguidelineslaiddownbythelocalauthoritiestogetridofit.Thiswillensurethedangerous
substancesfromwhich the batteryhasbeenmanufactured donot pollute the environment.
135
TYRE(S)/PLASTIC/ELECTRICAL/ELECTRONIC PARTS/OIL FILTER
If yourRoyal Enfield’styre(s)/plastic/electrical/electronic part(s)/oil filter needtobe replaced,make sure youhand them
over toanauthorised recyclingagent or a Royal Enfield Authorised Service Centre.Theywill followthelocal authority’s
guidelines toget rid of themin an environmentallyfriendly manner.
CLEANING YOUR ROYAL ENFIELD
Avoid aerosol sprays;instead, use a biodegradable detergent or drywashtocleanyour Royal Enfield. Also, becautious
while discarding the cleaningsolvents. Hand them over to an authorised recycling agent or a Royal Enfield Authorised
Service Centre. Theywill followthe local authority’sguidelinestoget rid of theminanenvironmentallyfriendlymanner.
Thisnotedoes not constitute legal advice;please contact your local authoritiesor your nearest Royal Enfield Authorised
ENVIRONMENTCARE
Service Centrefor further guidance.
136
NOTES
Part No. RAM00010/A

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ROYAL ENFIELD OWNER MANUAL Interceptor 650

  • 2. FOREWORD Congratulations.Younowownapieceofhistory! TheRoyalEnfieldInterceptorisourheritage-inspiredmachine,builtforthemodern,intrepidtraveller. Withyournewmachine,wemarkthereturnofoneofRoyalEnfield’smostlovedclassicmotorcycles-theInterceptor. HarkingbacktoatimewhenallthatmatteredwasthattheCaliforniasunwasoutandthesurfwasup,thismotorcycleretainsthe charmthatmadeitlegendary. Designedtobesimpleandrobustwithsolidandpreciseengineering,theInterceptorhasbeenbuilttobeyourfaithfulcompanion onrides andadventures, bigandsmall.Poweredbyourbrand-newair-cooled648cctwincylinderengineandrobusttwincradle chassisdevelopedatourstate-of-the-arttechnologycentreintheUnitedKingdom,wehopeyouenjoyridingyourmotorcycleas muchasweenjoyedbuildingitforyou. This manual is your friend, philosopher, and guide when it comes to taking care of your motorcycle. In the pages that follow, you will find ways of looking after your machine so that it remains a reliable partner in your travels and exploration for decades to come. Please do avail of all the services at your nearest Authorised Service Centre to make sure that your motorcycle gets the right treatment which it so deserves. Please also read through the terms and conditions of warranty and other useful information in thismanualbeforeridingointothesunshine. Keepridingpure. ToknowmoreaboutRoyalEnfield,ourproducts,andothernews,gotowww.royalenfield.com
  • 3. 2 All information in this manual is based on the latest product information available at the time of publication. Due to continuous improvements, there may be discrepancies between the information in this manual and your motorcycle. Royal Enfield reserves the right to make production changes at any time without prior notice and without incurring any obligation to make the same or similar changes to motorcycle previously built or sold. “© Copyright 2018 Royal Enfield (A unit of Eicher Motors Ltd.). All Rights Reserved. No part of this manual shall be copied, distributed or otherwise dealt without the express permission in writing from Royal Enfield”. All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical specifications are subject to change without prior notice. Avail further details on the products Repair and Maintenance Instructions at https://serviceinfo.royalenfield.com through paid subscription. NOTICE Disclaimer l This model fitted with “tubeless tyre” is provided with an inner tube. l Failure to use an inner tube in a spoked wheel will cause deflation of the tyre resulting in loss of motorcycle control. l The approved tyres marked with “TUBELESS” are suitable for use with inner tube. Part No. RAM00010/A / Qty. 500 / Oct. ‘18
  • 4. 3 CONTENTS Safety Definitions ........................................................................................................................................................................ 5 Personal and Motorcycle Information ....................................................................................................................................... 6 Safe Riding Tips / Guidelines ..................................................................................................................................................... 7 Rules of the Road ......................................................................................................................................................................... 13 Accessories and Luggage ............................................................................................................................................................ 16 Technical Specifications .............................................................................................................................................................. 18 Recommended Lubricants ......................................................................................................................................................... 26 Motorcycle Identification Numbers........................................................................................................................................... 28 Engine Number Details ............................................................................................................................................................... 30 Location of Key Parts................................................................................................................................................................... 31 Operation of Controls .................................................................................................................................................................. 34 Warning Indications and Safety Systems.................................................................................................................................. 45 Pre-Operational Checks .............................................................................................................................................................. 49 Running in Period ........................................................................................................................................................................ 50 Starting ......................................................................................................................................................................................... 52 Gear Shifting, Riding and Stopping ........................................................................................................................................... 56
  • 5. 4 CONTENTS Parking.......................................................................................................................................................................................... 60 Tools Kit ........................................................................................................................................................................................ 62 Minor Maintenance Tips ............................................................................................................................................................. 63 Long Trip Precautions .................................................................................................................................................................. 100 Washing Procedure ..................................................................................................................................................................... 102 Storage Precautions .................................................................................................................................................................... 104 TroubleShooting .......................................................................................................................................................................... 105 Wiring Diagram ............................................................................................................................................................................ 113 Periodical Maintenance Chart.................................................................................................................................................... 116 Service Maintenance Record ...................................................................................................................................................... 120 Warranty Terms and Conditions................................................................................................................................................ 123 Emission Warranty ...................................................................................................................................................................... 126 EVAP.............................................................................................................................................................................................. 132 Environment Care ....................................................................................................................................................................... 134 Notes ............................................................................................................................................................................................. 136
  • 6. 5 SAFETYDEFINITIONS Theinformationgiven under thetitles:Warning, Cautionand Note are for your safety and for the careand safety toyour motorcycleandothers. Pleasereadthesecarefullyandifdisregardedmayresultininjurytoyourselforothersanddamages tothe motorcycle. NOTE Indicates important and useful messagesfor better understanding. CAUTION Thismessage,if disregarded, may result indamage to the motorcycle. WARNING Indicates a potentially hazardoussituation. Disregarding this message may result ininjury to rider or other persons.
  • 7. 6 PERSONALANDMOTORCYCLEINFORMATION Name Door No./Street Locality/Town City Country Contact Res : Off : Mobile : Email : Licence No. Valid till : Model Color : Engine No. VIN. No. Tyre make Front : Rear : Tyre Nos. Front : Rear : Battery make Battery No. Sold by Date of Sale
  • 8. 7 SAFERIDINGTIPS/GUIDELINES n Before operating your new motorcycle, we request youtocarefullyread and followthe operating and maintenance instructions detailed inthis manual for the safety of your own, your motorcycle, and also that of others. n Knowand adhereto the rules of the road withrespect toyour driving country. n Before starting the motorcycle, checkfor proper operationof brakes, clutch, gear shifter, handle bar controls,tyre pressures,fuel and oil levels,etc. n Use onlygenuine Royal Enfield spare partsandapproved accessories. Use of other manufacturer’spartsmayaffect the performance of your motorcycleand render themotorcycle void of warranty. Visit your RoyalEnfield Authorised ServiceCentre fordetails. n Whenever refuelingyour motorcycle,please exercise utmost cautionand carefullyobserve thefollowingguidelines. « Refuel ina well ventilated area with the engine turned off condition. « Open thefuel filler cap slowly. « Switch OFF mobile phones and other hand held electronic devices. « DONOT smokeand pleaseensure thattherearenoopenflamesor sparksnearthe motorcycle,whenrefuellingOR servicingthe fuel system.
  • 9. 8 SAFERIDINGTIPS/GUIDELINES WARNING Royal Enfield cautionsyouagainst theuse of certainnonstandard partssuchasaftermarket andcustommade extended front forks or suspensions, whichmay adversely affect performance and handling. Removing or altering original parts may adverselyaffectperformance and could result inaccident. n A new motorcycle must be operated according to the special running-in-procedure. See running-in-procedure mentioned inrespectivesection. n Operate motorcycle only at moderate speeds and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions. n DO NOT exceed the legal speed limit or ride too fast for existing conditions. Alwaysreduce speed when poor riding conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control. « DONOTfill the tankto itsbrim. Please fill fuel till thebottomof anti splashplate,soastoleavesufficient air space in the fuel tankto allowfor fuel expansion.
  • 10. 9 SAFERIDINGTIPS/GUIDELINES NOTE If you are aninexperienced riderwerecommend thatyou obtainformaltrainingoncorrect motorcycleriding techniques andbecomethoroughlyfamiliarwith the operationofyourmotorcycle.Newridersshould gainexperience under various conditionswhile driving at moderate speeds. Pay strict attention to road surfaces and wind conditions. Any motorcycle may be subject to the following upsetting forces: « Wind blasts from passing vehicles. « Roughor uneven road surfaces. « Slippery road surfaces. Theseforcesmayaffect thehandling characteristicsof your motorcycle.If thishappens,reduce speedof the motorcycle toa controlled condition. Donot applybrakeabruptly. n Operate your motorcycle defensively. Remember that a motorcycle does not afford the same protection as an automobile inan accident. One of the most commonaccidentsituations occurs when the rider / driver of the other motorcycle / vehicle fails tosee or recognise a motorcycle and turns intothe oncomingmotorcyclist.
  • 11. 10 SAFERIDINGTIPS/GUIDELINES n Wear an approved helmet, clothing, and footwear suited for riding a motorcycle. Bright/light colours are best for greater visibility intraffic, especiallyat night. Avoid loose,flowing garmentsand scarves. n Whencarryinga pillionrider, it is your responsibilityto instruct themon proper ridingprocedures. n DO NOT allow other individuals, under any circumstances, to operate your motorcycle unless you know they are experienced, licensed ridersand are thoroughly familiar with the operating conditionsof your motorcycle. WARNING Regularlyinspectshockabsorbersand frontforksandlookfor leaks.Replace wornoutparts.Wornout partscanadversely affect stability and handling. WARNING Foryourpersonal welfare,allthe listed serviceand maintenance recommendationsshouldbeperformed.Lack of regular maintenance at thesuggested intervalsmayaffect thesafe/durability/longevityoperation of your motorcycle.
  • 12. 11 SAFERIDINGTIPS/GUIDELINES WARNING Avoid anycontact withthe exhaust systemwhenhot.Wear clothing that will completely cover the legswhile riding. The exhaustsystem getsveryhot whenthe engine isrunningand remainstoo hot totouch, evenaftertheengine isturned off. Failure to wear proper or protective clothing could result in seriousinjury. WARNING Exhaust gas contains poisonous carbon monoxide and chemicals, known to cause cancer, birth defects or other reproductivedefects. WARNING Motorcycle batteries containlead, acidsand chemicalsknowntocausecancer,birthdefectsor other reproductiveharm. Exercise extreme cautionwhile handlinga battery, wash hands thoroughly whenever a battery is handled.
  • 13. 12 WARNING ConsultyourRoyalEnfieldAuthorisedServiceCentreregardinganyquestionsorproblemsthatoccurintheoperationofyour motorcycle. Failure to doso mayaggravate aninitial problem, cause costlyrepairsand jeopardize your personal safety. WARNING DO NOT tow a motorcycle. The steeringand handling of the towed motorcycle will be impaired due to theforce of the towline. If a motorcyclemust be transported, usea truckor a trailer. WARNING DO NOT pull a trailer behind a motorcycle.Towing a trailer may causereduced braking efficiency, tyre overloading and SAFERIDINGTIPS/GUIDELINES unstable handling, asit may cause loss of control of the motorcycle inthe front, leading to anaccident.
  • 14. 13 RULESOFTHEROAD n Be sure your number plate isinstalled in the positionspecified bylawand it isclearly visible at all times. n Ride atasafe speed that isconsistent withthe typeof road surfaceyouare on.Paystrict attentionwhile ridingonthe following surfaces : « Dusty « Oily « Icy « Wet « Sand n Watchforloose debris,suchasleaves, slippery substancesorgravelthat canhamper thestabilityofyour motorcycle. n Keep to the correct sideof the road centre line whenmeeting oncoming vehicles.
  • 15. 14 RULESOFTHEROAD n Actuateyour turn signalsand exercisecautionwhen passing other vehicles going inthe same direction. Never tryto passanother vehicle going inthe same direction at street intersections, on curves, or whengoing up/or down ahill. n At street intersection give the right-of-way to the motorcycle on your left or right. DO NOT presume you have the right-of-way. n Adhere totherulesof theroadwithrespect toyour countrywhenpreparingto stop, turnorpass.Whileturningeither right or left, watchfor pedestrians, animals,as well asother vehicles. n All traffic signs, includingmanual controlsat intersections,should be obeyed promptly. SLOWDOWN at traffic signs near schools and CAUTION signs at railroad crossings. n When intending toturn, signal at least 100 feet (30.5meters) beforereachingthe turning. Beclose to the centre line (unlesslocal rulesrequire otherwise),slowdownand then turncarefully. n Never jump a traffic light. When a changeisimminent fromGOtoSTOP(or vice versa)at intersections, slowdown and wait for the light to change togreen. Never runthrough a yellow or red traffic light. n DO NOT leave the curb or parking area without signalling. Be sure your way is clear to enter moving traffic. A movingline of traffic always has the right-of -way.
  • 16. 15 SIDE VIEW MIRRORS Yourmotorcycle isequipped withconvex mirrorsand have a curved surface. This typeof mirror is designed to give a muchwider view of the rear than a normal flat mirror. However, vehiclesand other objects seen in this type of mirror will looksmaller and farther awaythan when seenin a flat mirror. Use care whenjudging the size or distanceof vehicles / objectsseen inthese mirrors. NOTE Toestablish the relative distance of vehicles /objectsbehind your motorcycle throughthemirrors,adjust eachmirror in sucha way, that a small portionof your shoulder isvisible and alarge portionbehind your motorcycle isseen clearlywith RULESOFTHEROAD reference to your ridingposture. n Whenparking themotorcycle,parkona firm and flat surface to prevent it fromfalling over. n Protect yourmotorcycleagainsttheft.Afterparkingyour motorcycle,ensurethat the steeringhead islockedand then remove the ignitionkey.
  • 17. 16 ACCESSORIES AND LUGGAGE Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested alongside the motorcycle. Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying additional weight. (Max. pay load: 200 kg) Please adhere to the following guidelines when carryinga pillion, luggage or when fitting any accessories. n Keep luggageweight concentrated close to the motorcycle and aslowaspossible;thisminimizes suddenshift inthe motorcycle’scentre of gravity. n n Distribute weight evenly onboth sides of the motorcycle. DO NOT exceed 110km/h / 70 mph when riding solo, carrying a pillion or payload on an accessory equipped motorcycle. n DO NOTload bulky itemsbehind the rider or add weight tothe handlebarsor front forks. n DO NOT exceed 6.6 pounds (3 kgs) maximum weight ineachRoyal Enfield Genuinemotorcycleaccessory pannier. n Re-checkthe luggage periodicallytoensureit issecured and will not shift whileriding.Accessoriesmounted loosely may affect the ridingof the motorcycle and affect the handling and stabilityof the motorcycle. n Large surfaces such as fairings, windshields, backrests and luggage racks can adversely affect handling of the motorcycle. Use Royal Enfield Genuine Motorcycle Accessories which are model specific and follow installation procedure.
  • 18. 17 ACCESSORIES AND LUGGAGE WARNING DONOTload weight or install accessories incorrectly onthe motorcycle. Doing so may affect the motorcycle’s stability, handling characteristics and safe operation and could result inan accident causing serious injury or loss of life. WARNING Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested alongside the motorcycle. WARNING Royal Enfield cautionsyou against use of nonstandard partssuchasaftermarket and custommade extended front forks which mayadversely affect the performance and handling of the motorcycle. Removing or altering original parts may adversely affect the performance of the motorcycle, causing an accident, which could result in serious injury or loss of life. WARNING DO NOT ignore model /design specifications. Doing soconstitutes bothmotorcycleand accessories misuse which may adversely affect the handling and performance of the motorcycle causing an accident, which could result in serious injury or lossof life.
  • 19. 18 TECHNICALSPECIFICATIONS ENGINE Engine Type ........................................... Inline Twin Cylinder, 4 Stroke, SOHC Bore ........................................................ 78mm Stroke ..................................................... 67.8mm Swept volume ....................................... 648cc Compression ratio ................................. 9.5:1 Max Power ............................................. 34.9 kw @ 7250 rpm Max Torque ............................................ 52.3 Nm @ 5150 rpm Idle RPM ................................................. 1200+80 RPM Starting................................................... E-Start Air filter element ................................... Paper element Lubrication ............................................ Forced lubrication, Wet sump with pump driven oil delivery Gear Box ................................................. 6 Speed Constant Mesh
  • 20. 19 Engine oil capacity Dry Fill ....... 3.9 litre / 1.03 imperial gallon Refill .......... 3.1 litre / 0.82 imperial gallon Engine oil grade .................................... TOTAL ELF MOTO 4 TECH SAE 10W50 API SL, JASO MA2, SYNTHETIC Fuel Supply ............................................. Fuel Injection Cooling .................................................. Air cooling IGNITION SYSTEM Ignition................................................... Digital Spark ignition o Ignition Advanced ................................ 11.25 BTDC Spark Plug .............................................. BOSCH UR5CC Spark Plug Gap ...................................... 0.7 to 0.8 mm TECHNICALSPECIFICATIONS
  • 21. 20 TRANSMISSION Clutch ..................................................... Wet multiplate Primarydrive .......................................... Gear Primary ratio ........................................... 2.05: 1 Gear box ................................................. 6 Speed Constant Mesh st Gear Ratio ............................................... 1 2.615:1 ......................................................... nd 2 1.813:1 ......................................................... rd 3 1.429:1 ......................................................... th 4 1.190:1 ......................................................... th 5 1:040:1 ......................................................... th 6 0:962:1 Secondary drive ...................................... Sprockets and Chain(5/8” Pitch) Secondary Ratio.....................................2.533:1 TECHNICALSPECIFICATIONS
  • 22. 21 CHASSIS Frame ..................................................... Steel Tubular, Double Cradle Frame Suspension Front................................................ 41 mm Front Fork, 110 mm travel Rear ................................................. Single Coil-over Shocks, 88 mm travel Hydraulic Disc Brakes ........................... Front and Rear with ABS system. ............................................... Front: 320 mm disc, ABS ................................................. Rear: 240 mm disc, ABS ................................................. ABS: BOSCH 9.1 Brakes: Brake Fluid: .............................................. Grade: DOT 4 ......................................... Capacity: Front: 50 ml Rear: 100 ml Tyre size: Front................................................ Rear................................................. Dual Channel ABS 100/90-18, Pirelli Phantom Sports Comp 130/70-18, Pirelli Phantom Sports Comp TECHNICALSPECIFICATIONS
  • 23. 22 TECHNICALSPECIFICATIONS TyrePressure: Solo Front................................................ Rear.................................................. Front................................................ 32 psi/2.20 kg/cm Rear.................................................. 39 psi/2.74 kg/cm Fuel Type ................................................ Unleaded Gasoline Ethanol content...................................... E10or less Minimum Octane Rating ....................... 91 RON (Research Octane Number) or Higher Induction ................................................ Fuel Injected Fuel tank capacity ................................... 13.7* litre / 3* imperial gallon Low Fuel Warning .................................. 2.9* litre /0.63*imperial gallon DeadStock.............................................. 0.75* litre /0.16* imperial gallon * The above values are approximate and the actual fuel filling capacitywill vary from the valuesmentioned. 32 psi/2.20 kg/cm 36 psi/2.53 kg/cm With Pillion Steering Lock.......................................... Combination Lock
  • 24. 23 TECHNICALSPECIFICATIONS WA RNING Using bulbs/ other electrical accessories other thanspecified rating maylead toover loading / erratic behaviour / premature failure of electrical system. Modificationsonthe motorcycle which arenot approved byRoyal Enfield may not only disqualify for warranty, but will alsoaffectsthe performance of the motorcycle. ELECTRICALS System .................................................... 12V - DC Generation.............................................. Alternator Alternator Output ................................... 156 W @ 1100 rpm Battery .................................................... 12V - 12 Ah VRLA Head lamp .............................................. 12V, H4 60/55 W Brake/Tail lamp ...................................... 12V, P21/5W (Halogen) Turn signal .............................................. 12V, R10W Instrument Cluster .................................. Digital Instrument Cluster withLCD Horn ........................................................ 320 Hz Low and 420 Hz High Tone StarterMotor .......................................... 12V, 0.8 KW
  • 25. 24 TECHNICALSPECIFICATIONS DIMENSIONS Rake ........................................................ 24 degrees Front Wheel ............................................ 18 M/C xMT 2.50 Rear Wheel ............................................. 18 M/C x MT3.50 Length..................................................... 2119 mm Width .............................................. 857 mm (with mirrors) Height .............................................. 1120 mm Wheel base ............................................. 1398 mm Ground Clearance................................... 174 mm
  • 26. 25 WEIGHTS Kerb weight (90% Fuel and Oil) ........... 213 kg Max. payload.......................................... 200 kg(Inclusive of rider mass) n Values / dimensions given above only for your guidance. n In view of continuous improvements being done on our products, the specifications could change without prior TECHNICALSPECIFICATIONS NOTE notice.
  • 27. 26 RECOMMENDEDLUBRICANTS Capacity * DO NOT Mix DOT 4 or other brake fluids together. Engine Oil CAUTION Use of wrongoil grade will reduce thelife of the moving partsand seriously affect performance. NOTE Recommendation subject to change without notice. Front Fork Oil Brake Fluid Brake System Capacity Grade DOT4 TOTAL ELF MOTO 4 TECH SAE 10W50 API SL, JASO MA2, SYNTHETIC 1st DryFill : 3.9 litre / 1.03 imperial gallons Grade Routine Oil Change : 3.1litre/ 0.82 imperial gallons Capacity Grade 2W 25 HPCL 473 ml / Fork Front: 50 ml Rear:100 ml Dual Channel ABS
  • 28. 27 ISO 14001 OPERATION CONTROL PROCESS As per the guidelines in ISO 14001 Environmental Management System, customers are advised to carry out timely replacement of engine oil, fork oil and brakefluid, ONLY througha Royal Enfield Authorised Service Centrefor the safe disposal of the used oilsto prevent environmental pollution. In case theoilsare replaced privately, it isadvised toensure theold / removed oilsare collected carefully and disposed through a certified disposal agency. Similarly, hazardous waste such as old / discarded batteries, tyres, tubes, cables, gaskets, oil filters etc. should also be disposed off carefully and properly, througha certified disposal agency.
  • 29. 28 MOTORCYCLEIDENTIFICATIONNUMBERS The VIN is a17digit number punched on the right side steering head tube in the formof label. Sample VIN : ME3 X X XX X X J X X X X X X X Manufacturer’scode Type of Frame Type of Engine Commercial Name Ignition System Transmission Type Production Year Assemblyfactory ProductionSerial No. (2017:H, 2018:J, 2019:K) (C-Chennai, K-Kanchipuram)
  • 30. 29 CHASSIS NUMBER MOTORCYCLEIDENTIFICATIONNUMBERS Punched on the steering head tube right side VIN INFORMATION LABEL It isillegal totamper withthe VIN information label as it is the only meansof identifications of the motorcycle. CAUTION M E 3 C N E H T 6 H K 0 0 0 0 0 1
  • 31. 30 ENGINE NUMBER - DETAILS The enginenumber is punched above the oil filter location. it isthemeansof identificationof the engineserial number and its production details. It isillegal to tamper with the engine number as it is the only means of identifications of the engine. Engine Family Engine Capacity Type of Cooling Transmission Fuel Feed Place of Manufacturing Production Month Year of Manufacturing (2017:H,2018:J, 2019:K) P 7 A 6 F K H 1 000086 (A - Jan., h - Aug., K - Sep., N - DEC.) (0-Chennai, 1-Kanchipuram) Production Serial Nos.
  • 32. 31 LOCATIONOFKEYPARTS 1. Horn Button 2. Turn Signal Switch 3. ClutchLever 4. Day Flash Switch 5. HighBeam/ LowBeamSwitch 6. Instrument Cluster 7. Ignition Switch 8. Malfunction Indicator Lamp 9. RPM(Tacho)Meter 10. Engine Kill switch 11. Electric Start Switch 12. Fuel Tank Cap km/h 00 2 0 00 4 0 00 6 0 00 80 00 100 00 120 00 14 0 00 16 0 00 18 0 00 20 0 00 E ODO 00 F km 00 OF F R.P.M. x 1000 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 ABS N 45 2 1 3 89 7 6 10 11 12
  • 33. LOCATIONOFKEYPARTS 1. Right Trafficator Rear 2. Right Trafficator Front 3. Horn 4. StarterMotor 5. BrakePedal 6. Brake LeverRear 7. Right Side Panel 8. Brake Lever Front 32 8 2 3 4 5 6 7 1
  • 34. 33 LOCATIONOFKEYPARTS 1. Left Trafficator Front 2. Left Trafficator Rear 3. Left Side Panel 4. SideStand 5. Centrestand 6. Gear Change Pedal 7. Spark plug 7 6 4 5 2 1 3
  • 35. 34 STEERING LOCK n Turnthe handle bar toextreme left or right position. n Pushthe keyinside at“OFF”position,pressandfurther turntoanticlockwise directionto lockthe steeringand remove the key. n OPERATIONOFCONTROLS IGNITION SWITCH To unlock, insert the key in steeringat lock position, and turn clockwise direction. NOTE n Key is common for ignition, petrol tank lock, steering lock and side panels. n Key can be removed from fuel tank, side panel only in locked position from the key slots. OFF: Steering unlock, ignition “OFF” ON: Steering unlock, ignition “ON”
  • 36. 35 OPERATIONOFCONTROLS FUEL TANK CAP n Lift keyflap onfueltank cap and insert key. n Turn key clockwise to open. n Presscap tolockwithkey inposition. n Remove key from cap and close flap WARNING n DO NOToverfill the fuel tank. n Fill fuel only till the bottomof anti splash plate. n Over fillingmay result ingasoline entering the EVAP canister and may damage the EvaporativeEmission System. CAUTION Gasoline vapour ishighly explosive.Please ensure there are noopen flames or sparksnearby while refueling andfill fuel onlyina wellventilated area. Pleaseensuregasolinedoesnotspillonpaintedsurfaces.Incasefuelspillsoverthepaintedsurfaceswipeitoff immediately as it mayleavea permanent stain. Do not smoke while refuelingor whenfuel tankcap isopen.
  • 37. 36 FUEL FILLING LEVEL 1. Fuel filler collar 2. Anti splashplate OPERATIONOFCONTROLS 3. Maximum fuel level ENGINE KILL SWITCH Engine "OFF" Engine "ON" CAUTION n Turn off ignition switchwhen engine is not running. Failure to do sowill discharge the battery due tothe headlamp being continuously "ON".
  • 38. 37 OPERATIONOFCONTROLS E-START SWITCH Depress and hold untill engine starts for a maximum of 5 seconds. HI BEAM / LOW BEAM SWITCH High beam Low beam HORN Pressthehorn button to sound horn. n When the headlamp is in ON condition “High / Low beam” will be selected by toggling the switch. Highbeamindicator lamp located ininstrument cluster will glowwhen high beamisselected.
  • 39. 38 OPERATIONOFCONTROLS TURN SIGNAL SWITCH "OFF" (Push to cancel) Right turn signal "ON" Left turn signal "ON" DAY FLASH Press theswitchfor Dayflash. Pushthebuttonfrom“OFF” positiontoeither left orright before turning as neededand restore to“OFF” positiontostop blinking.
  • 40. 39 OPERATIONOFCONTROLS SIDE PANEL LEFT n Toaccesstheleft side panel remove theseat andretainingscrew, pulland disengage the side panel fromlocater and gentlyremove the side panel. SIDE PANEL RIGHT n Turn keyclockwise tounlock the side panel. n Pull the side panel along with keytogently remove the sidepanel.
  • 41. 40 INSTRUMENT CLUSTER This instrument cluster consists of the following: 1. Speedometer 2. Odometer 3. Selection Button 4. Trip Meter 'A' and 'B' 5. Turn Signal Indicator 6. Hi beam Indicator 7. Engine Malfunction Indicator 8. BatteryLow Voltage Indicator 9. Fuel Level Indicator 10. ABS Indicator OPERATIONOFCONTROLS 11. Neutral Indicator 12. Low Oil Pressure Indicator 13. Tachometer 1 2 4 9 3 13 5 7 6 81011 12
  • 42. 41 NOTE The last selection mode will be displayed whenever ignition isswitched "ON". 2. ODOMETER The default display inthe odometer isthe total kms/miles, the motorcycle hascovered 1. SPEEDOMETER The Speedometer indicates the speed at which motorcycle is travelling and has both kms/ OPERATIONOFCONTROLS miles calibration. WARNING It isillegal totamper withthe odometer display or reset the total kms/miles, themotorcycle hascovered. It isillegal to ride the motorcycle after disconnecting thespeed sensor of the motorcycle.
  • 43. 42 WARNING Do not attempt to changeany setting while riding the motorcycle. It maycause lossof control leading to an accident. 4. TRIP METER A AND B A light push for less than one second on the select button switch will change the display from odometer Trip ‘A’. Again another press onthe select button switchwill change the display from Trip ‘A’ toTrip ‘B’. NOTE 1. Set the displayasTrip ‘A’or Trip ‘B’ ascurrent mode. 2. Presstheselect buttonfor more than3seconds. 3. Automatically the display will become zero. OPERATIONOFCONTROLS 3. SELECTOR BUTTON The selector knob will help toselect between odometer, Trip ‘A’ or Trip ‘B’.
  • 44. 43 OPERATIONOFCONTROLS 5. TURN SIGNAL INDICATOR Indicates that either the left or right indicators are “ON”. 6. HI BEAM INDICATOR Indicates that the high beam head lamp is “ON”. 7. ENGINE MALFUNCTION INDICATOR LAMP AMalfunctioning indicator lamp (MIL) isprovided in the tachometer. Whenboththe ignitionandengine kill switchisin“ON” position and after vehicle isstarted,the MILwill glowforfewsecondsandswitch“OFF” thisindicatesthat all thefunctionsofElectronic fuel injection (EFI) system is functioning normally. In the event of any malfunction in the EFI system MIL will glow continuously.Itisrecommended totakethemotorcycletoanearestRoyalEnfieldAuthorised ServiceCentreforadetailed inspection and correction of EFI system.
  • 45. 44 OPERATIONOFCONTROLS 8. BATTERY LOW VOLTAGE INDICATOR When the ignition switch is turned in“ON” position, low voltage indicator symbol will glow. As soon as theengine isstarted thebattery lowvoltage indicator turns “OFF” automatically. Incase the batteryvoltageisbelow12 volt and thebatteryisnot charging when the engineis started,the batterylow voltageindicator will continue to glow inthe instrument cluster. CAUTION DO NOT ride the motorcycle if the battery low voltage indicator is glowing continuously and please get the charging systemchecked throughan Royal Enfield Authorised Service Centre immediately.
  • 46. 45 WARNINGINDICATIONSANDSAFETYSYSTEMS Your motorcycle is fitted with the following warning indications and safety systems: 9. FUEL LEVEL INDICATOR Thefuel level indicator indicates the level of fuel in thefuel tank. Thedisplaybarsofthefuelmeterfadestowardstheempty(E)whenthe fuelleveldecreases fromfulltank level (F). The last bar of thefuel level indication inthe instrument cluster will blinkcontinuously whenthe fuel is less than 3litre (0.8 imperial gallon). Please do not ride the motorcycle with the low fuel indication blinking continuously as it may not only result in the motorcycle running out of fuel, but will alsocause seriousdamagetothe fuel pump. Please refuel as soonasthe lowfuel indication starts blinking.
  • 47. 46 WARNINGINDICATIONSANDSAFETYSYSTEMS 10. ANTI-LOCK BRAKING SYSTEM (ABS) Anti-Lock Braking System (ABS) will help prevent the brakes from locking the wheels, during sudden application of the brakes at high speeds or at low friction surfaces. This will help the rider to have better traction and control over the motorcycle and prevent the motorcycle from skidding which can cause an accident. Intheeventofasuddenandhardapplicationofthebrakesbytherider,thesensorsinthebraking system will signal the ABS modulator to momentarily and continously reduce the hydraulic pressure andthereby prevent the brakesfromlockingthewheelswhile reducingthespeed of the vehicle. This will help the rider to control the motorcycle. An ABS indicator lamp is provided inthe cluster (as shown in the adjacent image) to warn the rider in the event of any malfunction of the ABS. When the ignition and engine kill switch are switched in “ON” position the ABS sign will glow and remain "ON" till the motorcycle attains a speed of 5 kmph / 3 Mph and turns “OFF”. This indicates the ABS is functioning properly. If the ABS indicator lamp does not switch "OFF" and remains continuously "ON" at higher speeds, it is recommended not to drive the ABS motorcycle. Get the brake system inspected and corrected through a nearest Authorised Royal Enfield Service Centre. Failure to do so can result in a serious injuries and loss of life.
  • 48. 47 WARNINGINDICATIONSANDSAFETYSYSTEMS CAUTION (ABS) ABSisa safetyfeature to help prevent lockingof wheelsduring panic applicationof brakes. It isby no meansa substitute for good riding practices and anticipatory braking. Please ridecarefullyand applybrakescautiously,especiallywhile cornering.ABS cannot estimatethe“weightshifts”and momentumof the motorcycle while negotiating a corner and therefore prevent skidding due tolossof traction. Please anticipatethestopping distance requiredfor thespeedoftraveland applybrakeswellinadvanceso astobring the motorcycle toa safe stop. Please applybothbrakes simultaneously to stop withbetter tractionand control of the motorcycle. Failure toadhere tothe above cancausean accident resulting inseriousinjuries and loss of life.
  • 49. 48 WARNINGINDICATIONSANDSAFETYSYSTEMS DO’S AND DONT’S : (ABS) 12. LOW OIL PRESSURE INDICATOR This indicator glows whenever the oil pressure is too low. When the ignition switch is in “ON” position with the engine not running condition the indicator goes off when the engine oil pressure is high enough / normal condition. 11. NEUTRAL INDICATOR This indicator glows when the vehicle is in neutral position. DONT’S DO’S n While starting the engine do check the ABS indicator glows “ON” and turnsOFF when the vehicle speed exceeds 5 km/h (3.1mph). n Please check thebrake fluid at “MAX” level inthe front and rear brake reservoir and ensurethere isno leakinthebrake systems. n Applyboth thebrakes simultaneouslyfor better efficiency. n In the event of theABS indicator remaining continuously “ON”, please takethemotorcycletoanearestAuthorisedRoyalEnfieldServiceCentre toinspect thebrakesystem. n DO NOT RELEASE the brake lever/ pedalwhenpulsationsarefeltduring hard application of the brakes in an emergencysituation. Thepulsations only indicate that the ABS is activated. n DONOTAPPLYonlythefrontORrear brake as it can lead to inefficient braking.
  • 50. 49 ROLL OVER SENSOR In the event of motorcycle falling over on either of its sides withthe engine runningand the gear engaged the roll over sensor will disable boththe ignitionand fuel systemsand switch“OFF” the engine. Thisistoprevent further damage to the motorcycle and the rider. Toreset the roll over sensor and reactivatetheignitionand fuel systems. n Ensure the motorcycle isparked upright on afirm surface. n Ensure gear is inneutral position and theneutral lamp isglowingin the instrument cluster. n Turn“OFF” ignition andswitch“OFF” engine kill switch, wait for a few secondsand turn“ON” the Ignitionand switch WARNINGINDICATIONSAND SAFETYSYSTEMS “ON” engine kill switch once again, tostart the engine. 13. TACHOMETER Thisindicates the engine speed inRPM. CAUTION When the indicator glows continously and if the engine speed is above idle, stop the vehicle immediately and get the engine inspected and corrected througha nearest Authorised Royal Enfield Service Centre. Failure to do so can cause engine damage.
  • 51. 50 PREOPERATIONALCHECKS WARNING For your personal welfare and safety,all the pointsmentioned above should beperformed periodically.Failure todoso may affect safe operation, damage your motorcycle and could result in anaccident causingseriousinjury or lossof life. Acareful checkonthefollowing aspectsmust be carried out everytimebefore ridingand especiallyafter longperiodsof storageto determineif anyadditional maintenance is necessary. 1. Adequate fuel inthe tankfor the journeyplanned. 2. Tyresfor correct pressure, abrasionsor cuts. 3. Ensure chainfor proper tension and sufficient lubrication. 4. Brakes, clutch, steeringand throttle for proper responsiveness. 5. Handle bar controls for smooth operation. 6. Engine oil level. 7. Wheel spokes for proper tightnessand damage. 8. Headlamp, tail lamp, brake lamp and indicator lamps for proper functioning. 9. Proper functioning of all the warning lamps in the instrument cluster.
  • 52. 51 RUNNING INPERIOD The Royal Enfield Motorcycle as you would be experiencing iscapable of consistent high speeds. However as with any new motorcycle, a “RUNNING-IN” procedure is essential to help in proper “Bedding-In” of the various moving parts in your motorcycle and toachieve optimum performance subsequently. 1. DO NOT exceed maximum specified pay load. 2. Warmup the engine for a few minutesat idlingspeed toallow engineoilto lubricateallthemovingpartsinthe engine beforeriding the motorcycle. 3. Avoid full throttleoperation and donot ride at constant throttlecontinuously.Vary thespeed by 10%while riding. 4. It is recommended to use half clutch condition when commuting in the city traffic condition alone (Engine RPM around idling to2000 RPM) at 1st gear condition. In Other gears and higher RPM avoid using half clutch which will proportionately reduce the clutchlife. Duringacceleration/deceleration disengagethe clutchcompletely, shift the gear and engage the clutch gradually (Not too slowly). 5. Ride at proper speed and avoid suddenaccelerationsand braking. 6. Avoid riding motorcycle continuously for over an hour, it is recommended totake brief stop.
  • 53. 52 RUNNING INPERIOD During the first 2000Kms of run, donot exceed the speed limits as shown in the table below. Motorcycle Speed Gear First 500 kms 501 - 2000 kms NOTE The belowtable indicates the recommended engine speed in rpmfor optimum performance of the engine. DistanceCovered Max.Engine Speed 0 to800 kms( 0 to 500 miles) 4000 rpm 800 to 1600 kms ( 500 to 1000 miles) 6000 rpm 20 kmph 15 kmph 1 30 kmph 25 kmph 2 40 kmph 30 kmph 3 55 kmph 45 kmph 4 70 kmph 60 kmph 5 85 kmph 75 kmph 6
  • 54. 53 STARTING n To shift into neutral, move the motorcycle back and forth gently, while simultaneously shifting the gear. Ensure gear is in neutral position and the neutral lamp is glowing in the instrument cluster. n Turn ignition key to “ON” position and engine kill switch on right hand side handle bar to “RUN” position .
  • 55. 54 STARTING n When both the ignition and engine kill switch is in "ON" position and after the vehicle is started, the MIL will glow for a few seconds and turns “OFF”, this indicates that all the function of the electronic fuel injection (EFI) system is functioning normally. In the event of any malfunction in the EFI system the MIL will glow continuously. CAUTION n In casethemalfunctionindicator DOES NOTturn “OFF”, get the motorcyclechecked throughanRoyal Enfield Authorised Service Centre for rectification. n Checkthefuellevel indicator intheclusterfor adequate fuelinthefueltank. Incase the last bar is blinking continuously, it indicates low fuel leve l in the tank. Please re-fuel immediately.
  • 56. 55 n Depress and hold electric start switch until engine starts for a maximum of STARTING n Disengage clutch by pulling in the clutch lever and hold it in depressed condition. NOTE Incase theenginedoesnot startwithin5second, releasestarter switchand waitfor about 5second before attempting to start the engine again. 5 seconds.
  • 57. 56 WARNING Please exercise extreme care while ridingthe motorcycle.Failure to do socanresult inanaccident causing injurytoyou or toother roadusers/ passerby. CAUTION If the enginedoes not start. DO NOT hold the starter switch in depressed condition for long periods, this will cause the batterytodrainbelowthethresholdlevelof10volt.PleasegetthemotorcyclecheckedthroughanRoyalEnfieldAuthorised ServiceCentreto identifyand correct the reasonfor not starting. CAUTION NEVER accelerate assoon as the engine starts, especially in cold condition. The engine should be allowed to run in idle RPM for at least 2 minute for the engine oil to circulate and lubricate all the internal moving parts and for the engine temperature to raise.Failure toadhereto thisimportant information will causeseriousdamage tothe engine internals. Accelerate only after the idlingRPMhas stabilised and it isconsistent. STARTING n Ensure side stand isin fullyretracted position. Failure to do so will cause the engine to switch“OFF” as soon asgear is engaged.
  • 58. 57 GEARSHIFTING,RIDINGANDSTOPPING The clutch lever must be fully depressed before attempting a gear shift. Failure to fully depress the clutchlever will cause a roughstart ORstalling of the engine besides causing damage totransmission parts. n Whenthe vehicle isinNeutral position,press gear shift lever downwithtoe toengage 1stgear. GEAR SHIFT PATTERN 1-- N -- 2 -- 3-- 4 -- 5-- 6
  • 59. 58 GEARSHIFTING,RIDINGANDSTOPPING CAUTION n Iftheclutchleverisreleasedabruptlyand throttle openingisdone insufficientlythemotorcyclewillhavearoughstart and cause the engine tostall. n If the accelerationisveryhighand clutchlever isreleased abruptly, it will cause motorcycletomovesuddenly,which willleadtolossof control leading toanaccidentresultingininjuryand orlossoflife torider/ otherroad users/ passed by, besidesdamage tothe motorcycle. n Always exercise utmost caution while releasing clutch and riding the motorcycle. n Lift gear shift lever up withtoeto shift to 2nd and subsequent gears. n As soon asthemotorcycle reachesa speed of 20 kmph in1st gear position,shift to 2nd gear and tohigher gearsas the speed of themotorcycle increases.
  • 60. 59 GEARSHIFTING,RIDINGANDSTOPPING NOTE Alwaysstart motorcycle withthe gear in neutral position. When the engine speed decreases or while climbing a gradient or running at a reduced speed, shift to the appropriate lower gear toprevent theengine fromstalling or straining topull. n Always shift to lower gears asappropriate whenever slowingdown tostop thevehicle. n Shift gearsto neutral position just before bringingthe vehicle toa complete stop always. n Close throttle fullyand release the clutchlever slowlyensuringthemotorcycle isinneutral positionand neutral lamp is glowing. n Stop the motorcycle in a safe place, turn “OFF” ignition and switch “OFF” engine kill switch.
  • 61. 60 n Selecta firm,flat surface. n Hold handle bar firmly in a straight position. n Lower centre stand, suchthat, boththe legsof thestand are restingona firmground. n Applypressureonthefulcrumleveronthecentrestandandpullthemotorcyclebackward. n Lockthesteeringandensurethehandlebarislocked firmly beforeremovingthekeyfrom the ignitionbarrel. PARKING MOTORCYCLE ON CENTRE STAND PARKING
  • 62. 61 PARKING WARNING Ensure bothstandsare fullyretracted before riding the motorcycle. Please exerciseextremecarewhileparking andensure it isparked ona firmand flat surfacetoavoid themotorcyclefrom falling over and causing injury to you or to others and damage tothe motorcycle parts. PARKING MOTORCYCLE ON SIDE STAND n Select a firm,flat surface. n Extend side stand. Tilt the motorcycle to the left side, till it is supported firmly on the ground.
  • 63. 62 TOOLS KIT The tool kit islocated in the right side panel of the motorcycle. S.No. Description Qty. 1. C Spanner 1 2. Allen Key 6mm 1 3. Allen Key 5mm 1 4. Allen Key 4mm 1 5. ExtensionTube 1 6. Ring Spanner 24 x 14 Combination 1 7. Screwdriver 06 x160 1 8. Double End Spanner 10 x12 2
  • 64. 63 MINORMAINTENANCETIPS The following simple maintenance activities will help maintaining your motorcycle. However, for an complete maintenance,we recommend youto get in touch witha Royal Enfield Authorised Service Centre. HAND LEVERS, CENTRE AND SIDE STAND PIVOTS n Cleanthe pivot pointsand ensure theyare free of anydirt, grime,rust, etc. n Lubricate thepivots. NOTE Wipe off theexcess lubricant to prevent dirt and grime fromaccumulating.
  • 65. 64 DRIVE CHAIN n Spraydrive chainwith recommended chaincleaningsolvent while simultane- ouslyrotating rear wheel. n Ensure the drive chain has been sufficiently and completelycovered with the cleaning solvent. If necessaryuse asuitable brushtoremovehard depositsfrom the chain. n Wait fora few minutesand cleanthechainthoroughlyfromanydirt,grime,etc. n Rotate rear wheel slowly and simultaneously apply recommended chain lubricant onthe chain links. n MINORMAINTENANCETIPS Wipe off excess chain lubricant after a few minutes with a clean cloth.
  • 66. 65 MINORMAINTENANCETIPS CAUTION Use of wrong grade or spuriousoilscanseriously affect motorcycle performance and damage to movingparts. DO NOT over fill beyond the “MAX” level or allow oil level to drop belowthe “MIN” level. OIL LEVEL INSPECTION n Ensure motorcycle is inupright positionona firmandflat surfaceonits centre stand. n Start theengine and allowit toruninidlingrpm for about 2 minute and switch off the ignition. n Wait for 2 minute for the oil to settle down and check oil level through the window on RH cover of the engine. n The level iscorrect onlyif the oil is found betweenthe “MIN” and “MAX” marksonthe cover RH. n If necessarytop up ONLY withrecommended engine oil till the level isbetweenthe “MIN” and “MAX” markings.
  • 67. 66 n Remove the engine oil filler cap for adding the engine oil. n Place a clean tray under the engine oil magnetic drain plug. Remove it along withthe washer todrain oil completelyfrom the engine. WARNING DO NOT spill theengine oil. Store used oil in a separate container anddispose it. Avoid skin or body contact with the oil. Promptly wash the affected areas with soap and water till it is cleaned thoroughly. MINORMAINTENANCETIPS
  • 68. 67 n Place a container under engine oil drainbolt. n Gentlyapply thread sealant ondrain plug thread. n Insert the drain plug bolt along withnew washer. n n Tighten the drain plug bolt to 35 Nm. n Close engine oil filler cap. n Start and warmup enginefor 2 to 3minutesand thenturnit off.Check oil level MINORMAINTENANCETIPS NOTE through oil level window. Ensure the engineoilisdrained completely. Drain theoil completely and to avoid oil spilling. ENGINE OIL FILLING CAUTION DO NOT over fill engine oil as excess oil will spill over through the crankcase breathing systemand clog the air filter. Refill the engine oil recommended level.
  • 69. 68 CLEANING SPARK PLUG AND ADJUSTING GAP SPARK PLUG n Disconnect spark plugcaps fromthe spark plugs. n Locate spark plug spanner on the spark plug, loosen spark plug and remove it from cylinder head. n Checksparkplug for carbondepositsand centre electrodesfor unevenwear. n Clean spark plug by positioning it in a spark plug cleaning machine. MINORMAINTENANCETIPS Gap 0.7 to 0.8 mm. n Remove spark plugfrom the cleaning machine,checkand set electrode gap between 0.7 to 0.8 mm. n Position spark plug in the spark plug testing machine and check for proper functioning of the spark plug. n Always replacespark plugs ONLY as per recommended specification. n Apply a thin film of “anti seize” on the sparkplug mounting and threadsfix the spark plug by hand tightening. n Tighten spark plug to torque 10 to15 Nm by using a spark plug spanner.
  • 70. 69 MINORMAINTENANCETIPS BRAKE FLUID FRONT AND REAR n Ensure motorcycle isupright ona firmflat surface onitscentre stand. n Check brake fluid level inthewindowonfront and rear reservoirs. n The level iscorrect if the oillevel isbetweenthe “MIN” and “MAX” marks. n Openthe reservoir cover and remove diaphragmcarefullytotop up the brakefluid. CAUTION Brake fluidishighlycorrosiveand cancause damage to painted parts.Please ensure that brake fluid doesnot spillonany part of the motorcycle.Inthe event of a spill,please clean the area immediately witha soft wet clothtoavoid damageto theaffected part. DO NOT mix different brake fluid grades. Use ONLY DOT 4 Brake fluid. Front Brake Rear Brake n Top up only withDOT 4 brake fluiduntill level isbetween“MIN” and “MAX” marksin the reservoir. n Replace diaphragmcorrectly and closecover firmly. n Wipe off any excess / spilled brake fluid immediately with aclean cloth.
  • 71. 70 MINORMAINTENANCETIPS INSPECTION OF TYRES AND WHEELS n Checkandremovestone,splinters,nailsorotherparticlesembeddedinthetyretreads. n Periodicallyinspect wheelsfor spokes damageandwheel rimfor wobblingor runout. n Checkuniformseatingofthetyrebeadingontherimwheneverthetyreisreassembled. n Useonlyrecommendedtyresandtubes,inflatedtocorrectairpressureasgivenbelow. n Inspect the tyresperiodicallyfor tread wear, cracksand cuts. Minimum tread depth : Front tyre : 1 mm Rear tyre :2 mm Front Rear Solo 32 psi/2.20 kg/cm 36 psi/2.53 kg/cm With Pillion 32 psi/2.20 kg/cm 39 psi/2.74 kg/cm
  • 72. 71 MINORMAINTENANCETIPS FRONT WHEEL REMOVAL n Ensure motorcycle is upright on a firmand flat surface. n Place a woodenblock onthe front end of engine tosupport the motorcycle and ensure front wheel is off the ground by minimum 2 inches. n Fromwiring harness RH side disconnect the speedo drive coupler. n Loosen thepinchbolt on the front fork bottomright side. n Remove the axle nut alongwithwasher,holdthe wheel axle onthe right side and loosen hex nut on theleft completely. n Remove axle nut and washer from wheel axle.
  • 73. 72 MINORMAINTENANCETIPS n Placea 4mmthickwoodenpieceor cardboard sheet betweenthebrakepadstoavoidpadsactivationintheevent the front brakelever isaccidently pressed. n Take care not to damage the front brake disc or toneringasit will affect the brakingsystemand ABS. n Tap and remove the front wheel spindle, gently tap axle from left side while supporting wheel at the bottomthenremove axle fromthe right side. Do not pressthe brake lever when front wheel is removed as this will result in the brake pads coming too far out of the brake caliper. CAUTION Take care to secure the wheel spacers and speed sensor while removing the axle from the forks. n Slide out the front wheel fromtheforks. CAUTION
  • 74. 73 FRONT WHEEL REASSEMBLY n Remove the woodenpiece / cardboard sheet placed betweenthe brake pads n Locate speedodrive toitscorrect positiononthe right side. n Locate stepped spacer tothe wheel hub onleft side. n Insert thewheelalongwithspeedodriveandspacer betweenthe forkends.Ensure the brake discislocated between thebrake pads. n Supportfront wheel at thebottomand ensurethemountingholesarealigned toinsert thewheel axlealong theright side fork end. Gentlytapaxleintowheeltillthethreaded portionof axle isfullyvisibleon the left side fork end. n Assemble washer and nut on axle. n Hold the wheel axle firmly on right side and tighten axle nut firmly on left side to a torque of 70Nm. n Tighten pinchbolt completely onforkend to atorque of 25 Nm. MINORMAINTENANCETIPS
  • 75. 74 n Rotate wheel to checkfor smoothrotation. n Connect the speedowire coupler and check for proper working of speedometer. n Pressbrakelever and check frontbrake efficiency. CAUTION Please exercise utmost caution while reassembling the frontwheel onthe motorcycle. please ensure the wheel isfitted correctlybefore attempting to ride the motorcycle. Failure to do so may result in the motrocycel not performing correctly, may lead to an accident causing injury to you / other road usersand maylead toloss of life. MINORMAINTENANCETIPS
  • 76. 75 MINORMAINTENANCETIPS REAR WHEEL REMOVAL n Ensure motorcycle isupright ona firmand flat surface withthe rear wheel atleast 6 inchesraised above from thesurface. n Observe and markthe alignment indexes onboth chain adjuster on left and right side swing arm. n Loosenthe locknutsand adjusternutsfullyonthe left and right side chainadjuster.
  • 77. 76 n Hold wheel spindle onleft side firmly and loosen hex nut on right side. n Remove the nut and washer from the wheel spindle. n Push rear wheel fully into the swing arm. n Supportrear wheelfrombottomandpulloutwheel spindle fromtheleftside swing arm. n Release the brake hose gently and remove caliper assembly from swing arm on MINORMAINTENANCETIPS right side. n Ensure brake hose doesnot get damaged or kinked while removing. n Support caliper assembly suitably and away from swing arm. n Releasethechainfromthesprocketand ensure it doesnot getjammedordamaged when removingrear wheel. n Remove supportfromwheelbottomand gentlyslideoutrear wheelfromtheswing armwithrear sprocket, brake disc andspacers. CAUTION
  • 78. 77 MINORMAINTENANCETIPS Donotpresstherearbrake pedalwhentherearwheel isbeingremovedasthiswillcause thebrake padsto dislocate from thebrakecaliper. CAUTION n Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid activation of brake pads if rear brake pedal is accidentally pressed. DONOT pull up the rear brake pedal tolift or raise the motorcycle for anyreason. CAUTION
  • 79. 78 REAR WHEEL REASSEMBLY n Ensurethatthelongsteppedspacerislocatedonthebrakediscsideandtheshortspacer islocated onthe sprocket sideof the wheel hub firmly. n Ensure that thechain adjuster are located properlyinside theswing armleft and right sides. n Locate caliper assembly on the tab along theswing arm right side. n Locate rear wheelwiththe sprocket totheleft sideensuring the brake discin-between the brake pads onright side. n Lift up the rear wheel and ensure that theslotsintheswingarm brake caliper bracket holesin chainadjustersandthe centrehole in the hub are aligned. n Support rear wheel suitably andinsert rearwheel spindle alongthe leftside swingarm intothe wheel hub. n Ensure thatthelongsteppedspacer islocated alongthebrakesideandthe short spacer MINORMAINTENANCETIPS is located along the sprocket side on the wheel hub.
  • 80. 79 MINORMAINTENANCETIPS n Tapspindlegentlyintowheel hubslot till the threadsare completelyvisibleonthe right side. n Assemble the drivechain on the sprocket andensure it isseated correctly. n Checkfor free and smoothrotationof the rear wheel. n Assemble washer and hex nut on wheel spindle on right side.
  • 81. 80 DO NOT TIGHTEN HEX NUT FULLY n Tightenchain adjuster nutsonleft and right adjuster suchthat the index marksare aligned correctlyonbothsides of the swing arm. n Checkand ensure correct chaintension and wheel alignment. n Hold spindle firmly onleft side and tighten hex nut onright side set torque to 70 Nm. n Locate the brake hose inthe clips along the swing arm right side. n Checkrear brake for proper operating efficiency. CAUTION Pleaseexercise utmost caution while reassembling therear wheel onthe motorcycle. Please ensurethewheel isfitted correctly before attemptingto ride the motorcycle. Failure todosowill result in poor performance of motorcycle whichmaylead toanaccident causinginjuryto you/ other road usersand may lead to loss of life. MINORMAINTENANCETIPS
  • 82. 81 MINORMAINTENANCETIPS ADJUSTMENTS - CLUTCH n Loosenthecable outer lock nut . n Turnthe nut clockwise to reduce the playor anticlockwise toincrease thefree play. n Tighten lock nut after adjustment isdone. n Check free play 2to3mmat clutchleverpivotonhandlebar end,ifdesiredfree playisnot achieved readjust. REAR BRAKE LIGHT The brake light glows once youpressthebrakelever. If brake light isnot glowing, check the brakelight switch wire for proper connection.
  • 83. 82 MINORMAINTENANCETIPS DRIVE CHAIN TENSION (Free Play 20-30 mm) Parkmotorcycle up right on a firmand flat surface. n Ensure the motorcycle isin neutral position. n Measure the drive chainfree playas shown.Thedrivechainfreeplayis20mm to 30 mm. 1. If the drive chainfree playis found to be incorrect adjust as follows: a. Loosen the axle nut of the rear wheel axle. b. Loosen the lock nut ontheadjuster at bothend of the swingarm. c. To reduce thefree play, tightentheadjuster nut onthe adjuster evenly. n
  • 84. 83 d. To increase the free play,loosentheadjuster nutsevenly and pushtherear wheel forward. e. Check thechainfor correct chain tension. f. Ensure that the index marks on the adjuster and swingarmare same onbothleft and right side of the swingarm. g. Hold spindle firmlyto the left side and tightenrear hex nut to a torque of 70 Nm. h. Tighten the adjuster locknut using a 24mm spanner. MINORMAINTENANCETIPS WARNING Chain slackness beyond 30mm will lead to chain slippage and may also cause increased wear rates to chain and sprockets. Maintaindrive chainslackness withinthespecified limitsat every1000 kmsinterval. Please ensure thebothwheelsarealignedcorrectly,afteradjustingthe chainandbeforetightening therear wheelspindle nut.
  • 85. 84 BATTERY AND MAINTENANCE n The Motorcycle isprovided with 12V - 12 Ah battery. n Thebattery must be periodicallychecked for cleanlinessand corrosionfree MINORMAINTENANCETIPS terminals. NOTE The poor contact or loose fitment of batteryterminalsmaycause ECU failure. DISMANTLING n Switch “OFF” the engine and remove ignition keyfrom the key barrel. n Disconnect battery negative(- ve) terminal bolt.
  • 86. 85 MINORMAINTENANCETIPS n Remove 3Nos.Hex head boltsfromtool box to access thebattery. n Disconnect battery positive (+ve)terminal frombattery.
  • 87. 86 n Pull batterystrap (belt)downwards and release strap lock from battery strap bracket. n Loosenand remove hex flangehead screw frombatterystrap bracket. MINORMAINTENANCETIPS
  • 88. 87 n Removebatterystrapbracket frombattery tray. n Remove batteryfromtray. MINORMAINTENANCETIPS
  • 89. 88 MINORMAINTENANCETIPS WARNING Alwaysdisconnect the black negative (-ve)batterycable first and thenthe red positive (+ve) cable while removing the batteryconnections. NOTE For checking the battery voltagecontact Royal Enfield Authorised Service Centre or batteryservice centre.
  • 90. 89 ASSEMBLY n Assemble batteryin totray. n MINORMAINTENANCETIPS Place batterystrap bracket into batterytray.
  • 91. 90 n Locate and tighten flanged head screwinto batterystrap bracket. n MINORMAINTENANCETIPS Pull batterystrap(belt)downwardstofixstrap lockintobatterystrap bracket.
  • 92. 91 n Connectbatteryred positive (+ve) terminalbolt. n MINORMAINTENANCETIPS Locate and tighten3 nos. hex head boltsintotool holder.
  • 93. 92 NOTE Cleanthewireterminalsfree fromcorrosion and keep the terminals coated withpetroleumjelly. n Connect red batterynegative (-ve) terminal bolt. MINORMAINTENANCETIPS CAUTION Keepthered(+ve)positiveterminal and(-ve)negativeterminal cablesfirmlyconnectedtothe respectivebatteryterminals. Failure to do so mayresult in damage to the motorcycleelectrical system. CAUTION Connect the black (-ve) negative terminal after connect red (+ve) positive terminal only.
  • 94. 93 MINORMAINTENANCETIPS CHANGING ELECTRICAL COMPONENTS HEADLAMP BULB REPLACEMENT n Loosen the rim holdingscrew on top and take out the head lamp dome. n Disconnect electrical connections. n Thumb push and remove the bulb holding clamp gently. n Remove the bulb usinga clean and soft cloth.
  • 95. 94 n Positionthe newbulb inside the reflector suchthat the three projections on thebulb alignwith theslot on the reflector. n Refit the bulb holding clamp. n Connect the electrical connections. n Positionhead lamp dome onto thehead lampshell and tightenthe mounting screw on top. NOTE Never touchthebulb withyour fingers. Finger printswill etchthe glassand decrease bulb life apart from causing burnsto your fingers. MINORMAINTENANCETIPS Always hold the bulb with gloves and clean dry cloth during handling.
  • 96. 95 MINORMAINTENANCETIPS TAIL LAMP BULB n Unlock the side panel RH. n Remove the seat assembly by pulling seat lock cable. n Remove the tail light cover by unscrewing its mounting screw. n Hold the bulb, press inside and rotate anticlockwise to removethetail lightbulb fromitsholderusingacleancloth. n Replace the bulb 12V 21 / 5Wusing a soft clean cloth. n Re-assemblethetaillightinthereverseorderofdismantling process.
  • 97. 96 TRAFFICATOR BULB REPLACEMENT n Remove the screwfrom thetrafficator housing. n Open the indicator housing. n Remove the bulb holder with help of a screw driver. n Removethe bulbandreplace the sameusinga softandclean cloth. n Refit the holder toitsproper position. n Fix therubber gasket cover. n MINORMAINTENANCETIPS Assemble the indicator housing cover.
  • 98. 97 MINORMAINTENANCETIPS FUSE AND FUSE CARRIER WARNING Electronic Control Unit (ECU) may fail due toloose electricalconnections, loose battery terminals, etc. Hence,it isvery important to keep all the electrical connections are intact. n Thefuse carrier islocated under the seat. n Unlock side panel RH. n Release seat lock by pulling knob and remove the seat.
  • 99. 98 MINI BLADE FUSE USAGE LIST MINORMAINTENANCETIPS Fuse ID Color Rating Remarks Number 1 V 30 A Alternator 2 R-W 30 A Main Fuse 3 G-W 15 A Ignition Fuse-EFI 4 R 10A Signalling Fuse 5 BR 10 A Horn Fuse WARNING Please get the electrical system of your motorcycle checked thoroughlyand get the faults corrected immediatelyafter experiencing any fuse failure.Failure todoso mayresult inrepeated fusefailure. Usage of fuses other thanspecified rating will damage the complete electrical system. Fuse ID Color Rating Remarks Number 6 R 15 A Lighting Fuse (Head Lamp) 7 R-W 10 A Accessory Fuse 8 R 10 A ABS Fuse 9 R-W 25 A ABS Fuse
  • 100. 99 CLEAN AND REFIX : EVERY 5000 kms n Removethe screwfromthe side panel bottomside and remove side panel. n Removetheairfiltercoverscrewsandthentakeout n Pulloutfilterelementandcheckfordirt. Cleanfilterelementcarefully. MINORMAINTENANCETIPS AIR FILTER NOTE Usage of highpressure compressed air is not recommended to cleanair filter element. Fitment of air filter element isinthe reverse order of removal process. airfilterboxcover.
  • 101. 100 LONGTRIPPRECAUTIONS CHECKS PRIOR TO THE COMMENCEMENT OF A LONG JOURNEY n Service themotorcycle at Royal Enfield Authorised ServiceCentre. n Ensure sufficient quantityof fuel isalwaysavailable inthe fuel tankfor the journeyplanned. n Checkandcorrect tyrepressureifnecessary. CHECKS AFTER EVERY 1500 KMS OF RUN n Anyloosefasteners. n Conditionof the tyres. n Correct oillevel inengine. n Working of all lights and horn. n Proper drive chaintension. n Clutchcable free play.
  • 102. 101 LONGTRIPPRECAUTIONS ITEMS TO BE CARRIED n Tools kit. n Bulbsfor headlight, trafficator light and mini blade fuses (10 and 15 A). n Accelerator and clutchcable. n Sparkplug, spark plug cap. n Sparetubes.
  • 103. 102 PRECAUTIONS n Remove ignition keyand seal theignitionkey barrel slot usingadhesivetape. n Coverthesilencer tailpipe,hornandcontrolswitcheswithsuitableplasticbagsand tieitfirmlytopreventwater entry. n Wash the motorcycle only when the engine is in cold condition. n Do not remove side panel while washingto avoid water entry. n Brushengine area witha recommend noncorrosive solvent toremove dirt or grease. n Use lowpressure water jet toclean. n Neverspraywaterwithgreatforceonheadlamp,meter/clusterunit,flasher lights,front andrearwheelhubs,electrical connections and wires, control cables,EFIcomponents, sparkplug, battery, side panels. n Donot applyanycorrosive solvent onpainted surfacesor rubber parts. n Use lukewarmwater and mild detergent onthe painted componentstoremove dirt, etc. n WASHINGPROCEDURE Cleanmotorcycle thoroughlywith plainwater toremove the detergent.
  • 104. 103 AFTER WASHING n Ensure, the motorcycle is thoroughlydry by wipingwith a cleansoft lint free absorbent cloth or chamoisleather. n Remove all adhesive tapes. n Lubricate controlcables, pivotsfor footrest, side stand, centre stand,brakeandgear shifter linkages,drive chainetc. with lube oil. n Polish the painted and plated surfaces using recommended automobile polishing wax. n Start the engine and allowtorun at an idling speed for a fewminutes to warm up engine. n WASHINGPROCEDURE Drive the motorcycle slowly, applyboththebrakesintermittentlytodryup thewater inbrake pads. n If possible, use compressed air and blow off water particles from the obscure areas of the motorcycle, electrical connectionsetc.
  • 105. 104 In-case your motorcycle is not going to be used for a month or more,the following precautions should be taken. n Get the motorcycle serviced througha RoyalEnfield Authorised Service Centre. n Drainthe fuel completelyfromthe fuel tank and induction system. n Remove spark plug. Pour in about 5ml of clean engine oil through spark plug hole. Close the hole and crank engine several timesand refit sparkplug. n Clean drive chain thoroughly and apply Royal Enfield recommended chain lubricant. n Wipe off excesslubricant after 5 minutes of application. n Removebatteryfromthe motorcycle.Cleantheterminalstofreefromcorrosionandapplypetroleumjellytoterminals and cover boththemusing a plastic sheet. n Storethebatteryina cool,dry andwell ventilated place. n Cover the silencer withsuitable bagsto prevent moisture entry. Set the motorcycleon itscentre stand. n Applyanti rust solutionson all plated parts.Take care not toapply this solutiononchrome, rubber or painted parts. Storemotorcycle ina cleancovered area free of moisture and dust. n For re-use after storage, it ispreferable to get the motorcycleprepared through a Royal Enfield Authorised Service STORAGEPRECAUTIONS Centre to ensure the motorcycle isrestored toitspeak operatingconditions.
  • 106. 105 TROUBLESHOOTING WARNING Thetrouble shootingsectionof thisOwner’sManual isintended solelyasa guide for diagnosingproblems. Carefully read the appropriatesectionsof thismanualbeforeperforminganywork,repair and maintenanceoperationsnot listed inthis Owner’sManualshouldbeperformedbyyourRoyalEnfieldAuthorisedServiceCentreonly.Improperrepair /maintenance willresult in the motorcycle not functioning properlyor serious injury. CAUSES REMEDIES *Contact Royal Enfield Authorised ServiceCentre I. ENGINE FAILS TO START 1) Ignition switch in “OFF” position Turn Ignition switch “ON”. 2) Engine kill switch in “OFF” position Kill switch to “ON” position. WARNING Please get the electrical system of your motorcycle checked thoroughly and get thefaults corrected immediatelyafter experiencing anyfusefailure.Failure tocomply can result intorepeated fuse failures. Usage of fusesother thanspecified rating will damage the complete electrical system.
  • 107. 106 TROUBLESHOOTING CAUSES REMEDIES 3) No fuel in fuel tank Refill fuel. 4) Battery low voltage indicator is glowing Check battery for voltage/ chargingcircuit. continuously 5) Engine Malfunction indciator is glowing Get the motorcycle inspected through a Royal Enfield Authorised continuously ServiceCentre. 6) Sparkplug cap / lead not connected Fix cap / lead firmly. 7) Spark plug electrode dirty /fouled Cleansparkplug 8) Sparkplug insulationcracked Replace sparkplug. 9) Main or EFI fuse blown out Replace with new fuse. *Contact Royal Enfield Authorised ServiceCentre
  • 108. 107 TROUBLESHOOTING CAUSES REMEDIES II. ENGINE MISFIRING 1) Loosespark plug cap Fix cap firmly. 2) Sparkplug fouled Cleanspark plug or non specified heat range plug. 3) Any sensor loose connections *CheckMAPorEOTorTPSsensorwiring/couplerlooseconnections. 4) Water infuel tank * Clean fuel tank. Fill tank with fresh petrol. 5) Engine startsbut shutsof immediately Check if the MIL indicator continuously is glowing; If yes* 6) Engine misfires and runs erratically Check if the MIL indicator continuously is glowing; If yes* *Contact Royal Enfield Authorised ServiceCentre
  • 109. 108 III. POOR PICKUP 1) Brake pedal adjusted too tight *Re-adjust properly, refer to respective section. 2) Choked air filter Clean/Replace airfilter. 3) Drive chain tigh *Re-adjust properly. 4) Under inflated tyres *Inflatetocorrectpressure. 5) Accelerator cablefree playexcessive Adjust accelerator cable free play. 6) Clutch slipping *Adjust clutchcable free play. 7) Faulty fuel supply, fuelpump, *Remove fuel pump and clean. filter / injector blocked TROUBLESHOOTING CAUSES REMEDIES 8) Poor pickup Checkif the MIL indicator is glowing; If yes* *Contact Royal Enfield Authorised ServiceCentre
  • 110. 109 TROUBLESHOOTING CAUSES REMEDIES *Contact Royal Enfield Authorised ServiceCentre IV. ENGINE OVERHEATING 1) Lowengine oil level Check and top-up if necessary. 2) Clutch slipping *Check andcorrect. 3) Cylinder fins not clogged Cleanthecylinder finsat regular intervals. V. EXCESSIVE FUEL CONSUMPTION 1) Under inflated tyres Inflatetocorrect pressure. 2) Choked air filter Clean/ Replace. 3) Fuel leakage *Check and rectify,tankfloat unit,drainpipe,breather pipe, fuel line, pump, EVAP system.
  • 111. 110 TROUBLESHOOTING CAUSES REMEDIES *Contact Royal Enfield Authorised ServiceCentre VI. BRAKES POOR 1) Brake pad worn/ Unevenwear *Replace brake pads. 2) Oil / grease on disc. *Cleanand refit. 3) Spongybrake *Fill brake fluid and performbrake bleeding. VII. MOTORCYCLE WOBBLES 1) Under inflated tyres Inflatetocorrect pressure. 2) Loose/ Brokenspokes * Tighten/ Replace spokes. 3) Wheels misaligned *Ensure proper alignment. 4) Wheel rim runout * Rectify. 5) Tyres not fitted correctly *Refit tyrescorrectly.
  • 112. 111 VIII. ELECTRICALS Bulbs do not glow 1) Bulb fused * Replace bulb. 2) Fuse blown *Check and replace fuse. 3) Loose / improper connection * Check and correct. Horn not working 1) Fuse blown Checkandcorrect. 2) Loose connections Check andcorrect. Trafficators not working 1) Loose/ improper connections Checkandcorrect. TROUBLESHOOTING CAUSES REMEDIES 2) Bulb fused Replace. *Contact Royal Enfield Authorised ServiceCentre
  • 113. 112 IX. ELECTRONIC FUEL INJECTION (EFI) Malfunctioning indicator lamp (MIL) glowing continuously 1) Sensor coupler loose connection *Check for all EFI sensor coupler loose connection and correct them. 2) Any EFI sensor failure *Checkand replace thesame. X. ABS (ANTI LOCK BRAKING SYSTEM) TROUBLESHOOTING CAUSES REMEDIES 1) ABS indicator continuously “ON” Take the vehicle to servicecentrefor diagnosis. *Contact Royal Enfield Authorised ServiceCentre
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  • 120. PERIODICAL MAINTENANCE 116 Sl. No. DESCRIPTION PERIODIC MAINTENANCE I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. (**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms. 1 Engine Oil (#) 2 Engineoil filterelement (#) R R R R R R 3 Inlet and Exhaust valveclearance (**) I I I I I I 4 Spark plug I I I I R I I I R I I 5 HT lead for crack I I I I I I I I I I I Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50 Months Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30 Check level at every 1000 Kms or earlier and top up as required R R R R R R The maintenance schedule detailed here will help you to maintain your interceptor INT 650 motorcycle meticulously to get a long trouble free service. The schedule provided herein is based upon an average riding conditions and indicates the km/miles at which regular inspections, adjustments, replacements and lubrications are to be carried out. The frequency of the maintenance must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dust environment. Contact the nearest Royal Enfield Authorised Service Centre for expert advice and to carry out the required maintenance. 1.5 6 12 18 24 30 36 42 48 54 60
  • 121. 117 PERIODICALMAINTENANCE Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50 Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30 Sl. No. DESCRIPTION PERIODIC MAINTENANCE (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. (**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms. 6 Rubber hose, AirfiltertoThrottlebody I I I I I I I I I I I 7 Rubberhose, Inlet manifold/ Adaptor I I I I I I I I I I I 8 EvaporativeEmissionEquipmentrubberhoses I I I I I I I I I I I 9 Fuel filter- External R R 10 Airfilterelement C C R C R C R C R C R Clean/replace more frequently ifoperated in dusty condition 11 Vent Pipeunder airfilter box I I I I I I I I I I 12 Hose - Secondary Air I I I I I I I I I I I 13 Acceleratorand Throttlepulley cables free play 14 Clutch Cable/ leverfree play Adjust every 1000 Kms or earlier as required 15 Hand levers pivot point Lubricate every 1000 Kms or earlier as required I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean A A A A A A A A A A A Months 1.5 6 12 18 24 30 36 42 48 54 60
  • 122. 118 Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50 Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30 Sl. No. DESCRIPTION (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. (**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms. 16 Brake pads - Front and Rear 17 Disc Brake fluid level - Front and Rear 18 Rear brakepedal and Gearchangepedal pivot 19 Brake hose and Banjo Bolt - Front and Rear 20 Front Fork oil leak I I I I I I I I I I I 21 Steering tapper roller bearing Play I I I I I I I I I I I 22 Rear Wheel Drive Chain Lubricateand Adjust every 1000 Kms / Clean, Lubricate and Adjust every serviceor earlier as required 23 RearwheelCush rubbers I I PERIODICALMAINTENANCE PERIODIC MAINTENANCE I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean I I I I I I I I I I I I I I I I I I I I I I L L L L L L L L L L L I I I I I I I I I I I I I I I R I I I R I I 24 Spokes tightness / Wheel rimrun outfront andrear Replace oil at every 60000 kms or any work carried out whichever is earlier Months 1.5 6 12 18 24 30 36 42 48 54 60
  • 123. 119 PERIODICALMAINTENANCE Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50 Miles (x 1000) 0.3 3 6 9 12 15 18 21 24 27 30 NOTE Sl. No. 25 Batteryterminals (applypetroleum jelly) C C C C C C C C C C C 26 Battery electolytelevels (Notapplicable forsealed battery) I I I I I I I I I I I 27 Earth wireeyelet tightness I I I I I 28 Tyre wearpattern front and rear 29 Pivot-SideStand, Centre Stand L L L L L L L L L L L 30 RiderandPillion Footrest pivot 31 Allmounting fastenersin vehiclefortightness I I I I I I I I I I I (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. (**)- After Firstservice, Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespecified kms. PERIODIC MAINTENANCE I - Inspect (Clean, Adjust, lubricate or replace if necessary) L - Lubricate R - Replace C - Clean I I I I I I I I I I I L L L L L L L L L L L For Maintenance after 50,000 Kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorised Dealer / Service Centre. DESCRIPTION Months 1.5 6 12 18 24 30 36 42 48 54 60
  • 125. 121 SERVICE MAINTENANCE RECORD S.No. Date Brief detailsof work / service 9. 10. 11. 12. 13. 14. 15. 16. Job Card No. Royal Enfield Authorised Dealer kms/ miles
  • 126. 122 SERVICE MAINTENANCE RECORD S.No. Date Brief detailsof work / service 17. 18. 19. 20. 21. 22. 23. 24. Job Card No. Royal Enfield Authorised Dealer kms/ miles
  • 127. 123 WARRANTYTERMSANDCONDITIONS Royal Enfield warrants its motorcycle to be free from manufacturing and materials defects, under normal use subject to the following conditions. 1. Warranty shall bein force until the expiry of a period of 36monthsfrom thefirst dateofsale to the first customerand to any subsequent owners for thebalanceof theremaining period, until expiry of 36months fromthedate of first sale/registration of the motorcycle. 2. In order to effect Warranty, it is a prerequisite that the maintenance schedule prescribed by Royal Enfield in this Owner’s manual and warranty repairs if any, has been carried out at the AuthorisedDistributor’s service facility ORat their Authorised dealership’s service facility. 3. Record of all the regular servicesand periodical maintenance that have been carried out, along with proof of servicehistory will be required to be verified by the Authorised Distributor’s service facility OR their Authorised dealership’s service facility prior to carrying out a warranty service. 4. Proof of Ownership, in the form of Sales Registration OR Proof of Purchase documentation of the motorcycle, clearly mentioning the Engine and VIN numbers, must be provided to the Distributor’s service facility OR their Authorised dealership’s service facility. 5. During the warranty period, Royal Enfield’s obligation is limited to repair or replacing free of charge, such part or parts of the motorcycle which in examination shall be deemed defective in the opinion of Royal Enfield and/or their distributors/ authorised dealers. Such defective part/s, which has been replaced, shall become the property of Royal Enfield.
  • 128. 124 6. Cost of Consumables like fuel, oils etc, labour, shipping charges of replacement parts for any warranty replacement are chargeable to the customer. 7. Warranty is not applicable for the following parts: n Normal ageing of parts like rubber parts, tyres and tubes, hand grips, glass, plastic, soft items like seat rexene, cushion etc. n Dullness of chrome plated parts, discolourisation of chromed exhaust pipe / silencer, buffed parts, painted surfaces etc. n Normal wear and tear items such as control cables, brake pads/ shoes, clutch plates etc. n Electrical items like bulbs, wiring harness, switches, battery, fuses, electric start motor etc. WARRANTYTERMSANDCONDITIONS 8. Warranty will become void under the following conditions: n Damages due to lack of proper maintenance, periodicservices not carried out asper Royal Enfield recommendation etc. n Damages caused by any unauthorised repairs carried out in any part of the motorcycle. n Failures occurred due to use of non recommended grade lubricants, fuel or improper level. n Use of non genuine Royal Enfield parts. n Damages caused due to unauthorised alterations to any part of the motorcycle. n Use of accessories not supplied by Royal Enfield. n Motorcycle fitted with side cars.
  • 129. 125 WARRANTYTERMSANDCONDITIONS n Motorcycle used in rallies, off road, dirt track, races etc. n Motorcycle involved in accidents, collisions etc. n Damages that occur due to extreme operating conditions beyond the limitation or specifications as given by Royal Enfield, such as maximum load carrying capacity, engine speed etc. n Damages that occur due to long/improper storage, transportation of motorcycle etc. 9. Royal Enfield reserves the right to finally decide on all warranty claims. 10. RoyalEnfieldreservestheright tomakechangesinthemotorcyclewithout anyobligation toinstallthesechangesonpreviously sold motorcycle. 11. Royal Enfield authorised distributors and /or their dealers are independently owned and operated. They may hence deal with other aftermarket products for which Royal Enfield is not responsible for the performance, safety, quality, reliability and suitability of such products. Defects, if any in such parts OR that may arise in the motorcycle due to use of such parts is not liable to be covered by Royal Enfield and may render this warranty void. 12. There is no other express OR implied warranty in the motorcycle. Any implied warranty of merchantability or fitness is limited to the duration of this warranty. 13. To the fullest extent allowed by law, Royal Enfield and its authorised distributors and/or dealers shall not be liable for loss of use, inconvenience, loss of time, commercial losses or other incidental or consequential damages.
  • 130. 126 EMISSIONWARRANTY Incompliance withthe provisionsof Rule115(2) of theCentralMotor Motorcycle Rules, 1989, Royal Enfield certifiesthat the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its range of motorcycle, in normal use to which it may be subjected to. Royal Enfield furtherwarrantsthat if onexaminationbyitsRoyalEnfield Authorised Service Centre,the motorcyclefails tomeet the specified emissionstandards, thenthe Authorised Service Centreshalltakenecessarycorrective measures and shall, at itssole discretion, repair or replacefree of charge componentsof the emission control system tomeet the required emissionstandards. The method/s of examination todetermine thewarranty conditionsof the emission warranty related componentswill be at the sole discretion of Royal Enfield and / or our Authorised Service Centre and results of suchexamination will be final andbinding. If onexamination the warrantyconditions of thepart/s is/are not established, Royal Enfield willhave the right tochargeall,or partof the cost of suchexamination to the customer inaddition tothecost of the components. This emission warranty is valid for 30,000 Kms / 3 years from the date of first sale whichever earlier, to the first customer and is in addition to and parallel to the warranty policy, conditions and obligations laid down in the Owner’s Manual.
  • 131. 127 In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge the component/sasrequired.However,theconsumableslikefuel,lubricants,solvents,etcshallbechargeabletothecustomer as per actuals. Incaseanyofthecomponentscoveredunderemissionwarranty ortheassociatedpartsarenotindependentlyreplaceable. Royal Enfield will have the solediscretiontoreplace eitherthe entire assemblyor partsof the assembly throughsuitable repairs. Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace any part, in additiontotherepair orreplacement of thecomponentscoveredunder emissionwarranty,to establishcompliance toin- use emissionstandards. Suchrepairs / replacementswill be chargeable to the customer. All parts removed for replacement under warranty will become theproperty of Royal Enfield. Royal Enfield will not be responsible for the cost of transportationof the motorcycle tothe nearest Authorised Service Centre OR for any loss due to nonavailability of the motorcycle during the period of examination and repairs by Royal EMISSIONWARRANTY Enfield and /or their Authorised Service Centre.
  • 132. 128 EMISSIONWARRANTY Royal Enfield willnot beresponsible for anypenaltiesthatmaybe chargedby statuatoryauthoritiesonaccountof failure to comply with the in-use emission standards. The cost incurred tocheck emission of the motorcycle will havetobe bornebythe customer. Emissionwarrantywillbeapplicableirrespective of thechange of ownershipofthemotorcycleprovidedall theconditions as laid downin this document are met fromthe date of original sale of the motorcycle. THE WARRANTY SHALL APPLY IF THE CUSTOMER n Observes all the important instructions and anyother precautions listed in theowner’smanual. n Under all circumstances uses lubricants and fuel asrecommended by Royal Enfield. n Regularly obtainsand carries out maintenanceinaccordance withRoyal Enfield guidelines and enters the details in the Log book. n Immediatelyapproachesthenearest RE Authorised Dealer /Service Centreupondiscovery of failureto comply with the emissionstandard inspite of having maintained and used the motorcycle inaccordance withthe instructionsin the owner’smanual and having carried out suchrepairsand adjustments asmaybe required witha viewtoestablish such compliance.
  • 133. 129 EMISSIONWARRANTY n Production of a valid Pollution Under Control Certificate is necessary to claim Emission Warranty. n Producesthe owner’s manual and Log book for verificationdetails. n Producesreceiptscoveringmaintenance ofthemotorcycleisspecified intheowner’smanualfromthe date of original purchase of the motorcycle. n Produces valid certificate of Insurance and R TORegistration Certificate (R.C.Book). THE EMISSION WARRANTY SHALL NOT APPLY IF n A valid “Pollution under control” certificate isnot produced. n Themotorcycleisnot serviced by RE Authorised Dealer /Service Centre asper theservice schedule described inthe maintenance chart. n The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenanceor hasmet with an accident.
  • 134. 130 EMISSIONWARRANTY n Replacement partsnot specified and approved byRoyal Enfield havebeenused. n The motorcycle,orpartsthere of,hasbeenaltered,tampered withor modifiedorreplacedinanunauthorisedmanner. n The odometer isnot functioningor theodometer and / or itsreadinghas beenchanged / tampered with, sothat the actual distance covered cannot be readily determined. n The motorcyclehasbeen used for competitions, racesand rallies or for the purpose of establishingrecords. n On examination by Royal Enfield or its Authorised Dealer / Service Centre, if the motorcycle shows that any of the conditions stipulated in the Owner’s manual with regard to use and maintenance have beenviolated. n The motorcyclehasbeen runon adulterated / leaded fuel or lubricant other thanthose specified by Royal Enfield in the Owner’smanual or anyother document given tothe customer at the time of sale of the motorcycle. n The emission related components aretampered with. n All service and partsrelated billsand vouchers incurred duringthe tenureof the emissionwarranty isnot produced. n All maintenance activitiescarried out onthemotorcycle during the tenure of theemissionwarrantyare not entered in the log book.
  • 135. 131 TIPS TO BE ON THE RIGHT SIDE OF LAW n Always get your motorcycle checked to meet the emission regulations through an authorised emission checking centre. n Always carry a valid "Pollution Under Control" certificate with you, as and if applicable by law. TIPS TO REDUCE POLLUTION n Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal Enfield AuthorisedServiceCentre. n Use only Unleaded petrol (91 RON or higher) from reputed fuel pumps. n Ensure thefuel usedisnot adulterated. n Use correct spark plug asrecommended in the owner’s manual. n EMISSIONWARRANTY Use lubricants asper recommendationsgiven on grade / brand in the owner’s manual.
  • 136. 132 EVAPORATIVEEMISSIONCONTROLSYSTEMWARRANTY The following warranty appliesto the evaporative emission control system. Royal Enfield Motorswarrantsthe first owner and eachsubsequent owner,that thismotorcycle isdesigned and built so astoconform,atthe timeofsale,withapplicable regulationsspecifiedbytheevaporativeemissioncontrolsystemrelated partsfitted to thismotorcycle are free fromdefectsinmaterialsand workmanship whichmaycause this motorcycle not tomeet applicable regulations period of 24 Months fromthe date of first use of the motorcycle. The Warranty periodshallbegineitheronthedatethemotorcycleisdeliveredtothe first retail purchaserORfromthefirst date the motorcycle isused asa demonstrator OR asa display and/or trialmotorcycle. THE FOLLOWING ARE NOT COVERED BY THE EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY 1. Failureswhichmayarise asa result of misuse,alterations, accidentsOR nonperformance of routine maintenance,as specified in the Owner’s Manual. 2. Replacing, removing OR modifying any portion of the EVAPORATIVE EMISSION CONTROL SYSTEM (consisting of fuel tank,fuel tankcap, canister,purgevalve, throttle body,vapor hoses,fuel hoses and hose connectors)withparts not certified byRoyal Enfield.
  • 137. 133 EVAPORATIVEEMISSIONCONTROLSYSTEMWARRANTY 3. Lossof time, inconvenience, lossof motorcycle use or anyother consequential loss or damages. 4. Any motorcycle inwhichthe Odometer hasbeentamperedwithOR the speedo cablehasbeen disconnected for any reason OR isbrokenand not replaced immediately, due to whichthe exact distance covered cannot be determined. 5. Normal aging of partssuch asfuel hoses, vapor hoses, gasketsand rubber components. RECOMMENDATIONS FOR REQUIRED MAINTENANCE It is recommended that the routine maintenance of the motorcycle be carried out at specified intervals and any maintenance to the evaporative emission control systems should be performed only by an Authorised Royal Enfield Service Centre and usingonly genuine Royal Enfield spareparts.
  • 138. 134 ENVIRONMENTCARE BEAN ENVIRONMENTALLY CONSCIOUS RIDER You’veriddenthroughsome beautiful placeson your Royal Enfield.Won’t youlike tokeep themthatway? Here are some tipsto help youkeep those places unspoilt so that otherscan enjoythemtoo: ENGINE OIL While your liquid waste like engine oil, gasoline,coolant and other cleaningsolventsneed tobe regularlyreplaced,what happens to them? Make sure they are not dumped in the soil, down the sewers, drains, lakesor rivers around you. The simplest wayto doit istohave themdrained into a container whichyou canhand over toyour local recyclingagent or at yournearest Royal Enfield Authorised Service Centre. Theywill followtheguidelineslaid downbythelocalauthoritiesto get rid of it. BATTERY IfyourRoyalEnfield’sbatteryneedstobereplaced,handitovertoanauthorisedrecyclingagentorRoyalEnfieldAuthorised ServiceCentre.Theywillfollowtheguidelineslaiddownbythelocalauthoritiestogetridofit.Thiswillensurethedangerous substancesfromwhich the batteryhasbeenmanufactured donot pollute the environment.
  • 139. 135 TYRE(S)/PLASTIC/ELECTRICAL/ELECTRONIC PARTS/OIL FILTER If yourRoyal Enfield’styre(s)/plastic/electrical/electronic part(s)/oil filter needtobe replaced,make sure youhand them over toanauthorised recyclingagent or a Royal Enfield Authorised Service Centre.Theywill followthelocal authority’s guidelines toget rid of themin an environmentallyfriendly manner. CLEANING YOUR ROYAL ENFIELD Avoid aerosol sprays;instead, use a biodegradable detergent or drywashtocleanyour Royal Enfield. Also, becautious while discarding the cleaningsolvents. Hand them over to an authorised recycling agent or a Royal Enfield Authorised Service Centre. Theywill followthe local authority’sguidelinestoget rid of theminanenvironmentallyfriendlymanner. Thisnotedoes not constitute legal advice;please contact your local authoritiesor your nearest Royal Enfield Authorised ENVIRONMENTCARE Service Centrefor further guidance.